Just a guess but maybe your bullet is too small for the barrel. You see when you use a round lead ball for a BP rifle you have to have a tight seal other wise the powder charge will burn past the ball loosing proper pressure due to improper powder burn. This is why a lubed patch is used. The patch is a piece of cloth even a cotton tee shirt can be cut into patches. You place the lubed patch over the muzzle place ball on patch and seat the ball slightly into the barrel than cut excess patch material off and ram ball/patch home with ram rod.
Care must be taken to use the proper amount of black powder and the right type, for rifles its FFg NOT FFFFg.
Sabot bullets have a plastic sabot that fits around the projectile for a tight fit in the barrel also.
So you have to find what combination of patch and ball or sabot and bullet to fit the bore tightly. Then when the patched ball or sabot is tightly fitted in the barrel all the way back against the powder charge you will have proper powder ignition and the right back pressure for the maximum velocity for that powder charge.
Also you have to work your loads up following manufacture recommended powder loads.
So you need; right size lead ball ammo, right size patches, sabots, powder measure, patch knife, cleaning rod and ram rod besides percussion caps and BP powder.
When all is done right you will feel the recoil of the rifle, a boom, flame and smoke, when shooting black powder.
NOTE; Most use FFg and not FFFG for rifles the less the numbers of F's the slower the burn rate. So FFFFg is fast and FFg is slow.
The links below explain all you should need to know.
PS; Ignore the thumbs down obviously some one likes to discredit good information. I have used BP guns for most of my 50+ years on earth and have hunted game with them all over America.Black powder rifle shooting?
I'm not sure what your doing, but just so you know, there is FFG powder, recommended for rifles and FFFG for pistols. If your putting FFG powder in the gun, then you can't do anything wrong. I've never pushed the sabot down to hard onto the powder, we'll call it snug for lack of the right term. Then, I mark my ramrod with a small line so to make sure I am loading the gun the same way every time. Also, the black powder market has found that it is not recommended shooting a 209 shotshell primer. Winchester and Federal Fusion both make a true muzzleloading primer now and those are recommended.
There is always a flame that comes out of the end of the barrel, we just never notice it because we don't see it during daylight. At night, is when we will see this, or unde darker situations.
If your putting to much powder in the gun, your just wasting powder, because some will not burn and you'll just have more of a mess to deal with.
That is blackpowder shooting...perfectly normal.
How many grains are you using and how long is the rifle barrel? Loose powder, 90 grains normally does well with most bullets. If you're using pellets, use the 100. 150 is just a waste of money (especially in a short barrel).
That will obvouisly determine how much fire shoots out the other side. But it's normal
As long as the bullet is all the way down, you're fine. You can't pack it in too hard (you can but all you'll do is mash the tip of bullet which can affect groups and performance when hunting.
Just be sure you get the bullet all the way down though
Take you ram rod and drop it down the loaded barrel. If it bounced, the bullet is fully seated. If it does not bounce, the bullet needs to be pushed father.
Intentionally seat the bullet half way in the barrel and drop the rod, then seat it all the way and drop the rod again --- you'll see what I mean.
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