Well, ok - I guess that just about puts a wrap on this thread.
And there you have your answer! It could be dangerous grinding your powder, though that's how it was made in the first place. But hey, we all know the powder factories blew up multiple times, so it's gotta be dangerous. And, it doesn't make a dam bit of difference grinding it smaller because it'll have no effect anyway - even though smaller particles are spec'd for smaller guns, and real small particles are normally recommended for pan priming. Even though you grind your own, it won't work as well as factory bought...
Sometimes I wonder if there are special individuals taking on the chore of steering the uninitiated away from the do-it-yourself path of independence with fear tactics.
There was a fear I had of black powder guns - not wanting to wash after shooting because I 'knew' it was going to rust away. You know, guns and water don't mix! I'll bet a lot of guys never shot their black powder guns because they didn't want to wreck their pretty firearm. Just another fear.
Everything in life has some danger. The trick is understanding the mechanics and problems associated with whatever action you're taking on and dealing with them. Yeah, kids have lost fingers playing with fireworks, and a guy flew his lawn chair over the Los Angeles airport and would have been lost over the ocean had the airport controllers not spotted him. Some experiments (not knowing all the dynamics, or starting out small) can lead to big trouble. But grinding powder - come on. As far as I can tell, there's been no reported injuries from that particular action. Any close calls???
Ok - so this question has been kicked around before. Far as I can tell, it's been kicked long enough this time to figure out what's what.