I have been working with a Young Man in Tennessee that just recently Bought a Knight Mountaineer .45/1:20 (Dustin Garrison, The Guy I bought my Rice .45 Cal Barrel from) He is Shooting BH209 and has had the EXACT same problems i have had. He has had a Couple of Bullets barely Spit out of his Barrel as well, From just the Primer going off. I explained to him that Wool Felt (Even Though we are using Oversize) Simply won’t work, Reliably anyway.
What AMAZES me is HOW IN THE WORLD Can Spark from a 209 Shotgun Primer Go Through a Powder Charge and NOT SET IT Off??? That blows my mind!!! The first time i seen it happen, My bullet went about 15-20 Yards, Hit the Ground and Tumbled to a Stop, i sat at my Bench and Actually laughed

I asked myself WTF Just happened??? That was the END of BH209 and me RIGHT THERE!! I would NEVER Put trust in it after that, Especially on a Hunt.
It’s not the propellants Fault, They tell you on their Website.
When i talk about “Bore Riding” Bullets, i mean ZERO effort pushing them Down, Just the Weight of the Ramrod alone will take the Bullet to the Powder, My Bullets just “Kiss” the Rifling on the Way Down. I found out quickly that my Target Bullets do NOT Work with BH209, Then ad in my Wool Felt Wads. Simply Put, For MY Application BH209 is the Worst Crap out there!
Below is Copied and Pasted from Western Powder’s Website. Someone that gives a Hoot Should inform them that they are DEAD WRONG about loose Fitting Bullets and Accuracy, THEY COULDN'T BE MORE WRONG!!! I have had 2 different conversations with Lee Shavers (For those that Don’t know, Lee is a 2 time World Champion BPCR, And Muzzleloader Shooter, He competes to 1,000 yards) Lee took the time to talk Bullets, Loading, What to look for, etc. with me. Lee went in to Great Detail with me on 2 Things, Importance of Bullet Bases, And Loading Pressure, or lack there of. Lee Explained that a PERFECT Sized Bullet for HIM, was one that Just “Kissed” The Rifling on the Way Down, He explained that you should NOT have to Push on the Bullet to load it, It should Glide down, Then Give it a Slight Push against the Wad.
I have followed Lee’s Advice to the T and my Results have been STELLAR!! My Targets, and Videos Show Quite clearly that what i am Doing is Working
Western Powder’s Should Contact Lee Shaver’s and inform him That he has been Loading his Bullets Wrong all of these Years, Disregard His pile of trophies, Medals, Plaques, etc.
A muzzleloader is different than a cartridge gun, but many of the principles relative to the propellant are the same. The bullet is seated in the cartridge to create the pressure necessary to propel the bullet. A bullet in a muzzleloader needs to be compressed against the powder. The base of the bullet, or sabot needs to expand to hold the building pressure which propels the bullet. Imagine you placed a bullet 1 inch ahead of the case in a cartridge gun. The bullet most likely would not exit the barrel. This same principle works in a muzzleloader. Loose fitting bullets, like the typical Powerbelts, may be convenient to load, but lack sufficient compression to assure consistent ignition or accuracy.
Because there are no standards in muzzleloading barrels, the diameters vary between all manufacturers and at times within the same manufacturer. A Powerbelt may fit nicely in one and slide to the bottom of another. Just the simple act of carrying your gun in the field may allow the bullet to slide forward and when compression of the powder is lost the result is a misfire or poor accuracy.
We recommend a quality tight fitting sabot for the most consistent accuracy and ignition.