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The only way I think would result in this is if the load was loose. With the slug well off the charge the pressure had a lot of volume to expand in until it pushed the slug out of the barrel with out causing any damage. Signs of that happening is an unusual dirty bore after the shot.
That sounds right to me.
 
cant say for sure, but firing a muzzle loader indoors seems interesting
Back in the early 80s. It was raining and c ouple of us went to indoor range. Ughh. Told the guy we had muzzleloaders and asked if we could shoot an hour. He said yes as long as they wasnt centerfire rifles.we went back there and started shooting.well there were ouple guys busting loose with their pistols we each got in a lane and let the smoke roll.they started yelling and cussing at us.lol. so the manager came in there.he said it was ok but we decided be nice and said we would just go sit at the tables up front and watch them shoot. Then we would shoot after they left. Their exhaust fans in the back wasnt pulling all that smoke out fast enough. It was foggy. Hahaha
 
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