I don't have much experience with East Indian muskets, but I wanted to share with the group some experience with a "replica" of a percussion Officer's Belt Pistol that purported to be a copy of one carried by British officer. A friend of mine traded for it and was very pleased with it until he fired it. He first removed the lock and the breeched barrel, cleaned storage grease from the lock works and scrubbed the bore. It was smoothbore, 20-gauge, and he loaded it with (first) 30 grains of FFg, a cork wad, a measured charge of shot (No. 7-1/2, as I recall) and a card wad. It wanted musket caps. He shot it with that load two or three times then moved up to 40 grains of powder. One shot and he noticed that there was a gap starting between the breech plug and the breech end of the barrel. Long story short, he called me and when I arrived we did a detail disassembly. When we started to unscrew the breech plug, we found that it was not threaded at all and neither was the barrel. They were press-fitted ...... and soldered together! He hung it on the wall as a reminder and never fired it again, of course.
Not every piece you come across is built to the same standards, y'all. Be very cautious.
There floats my stick.
Tanglefoot
Back in the early 1980's a very cool fellow named Jerry Cunningham, when working for Montana Rifle Barrel Company, wrote a paper while tested a large number of barrels of various dimensions with all sorts of overloads and obstructions, including huge charges, multiple patched balls, and obstructions using barrels of 12L14, and 1214 Bismuth, free-machining carbon steels with a 69,000 psi tensile strength, 65,100 psi yield and a 15.3 % elongation.
With increasing numbers of round balls seated on the powder the lightest charge tested that bulged an octagon barrel was a .36 cal 13/16" X 35" with 400 grains of 3F, and four balls. The .45 cal. 13/16 " X 35" bulged when they got to 600 grains of 3F, with six balls, while the .45 cal 15/16" X 42" barrel bulged at 800 grains of 3F. The .50 cal. 7/8" X 35" barrel tested was of 1214 Bismuth, and bulged at 800 grains of 2F powder with eight balls. The .54 cal. 15/16" X 35" barrel, also of 1214 Bismuth bulged at 1000 grains of 2F with ten balls. The .58 cal. 1" barrel of 1214 Bismuth bulged at 1000 grains of 2F with ten balls, and the .62 cal. 1" X 35" barrel of 1214 Bismuth also bulged at 1000 grains of 2F and ten balls The largest of these bulges was .005" per side on the .50 cal 7/8" barrel. Obstructions also required pretty drastic charges to burst these barrels. The .36 cal 13/16 bulged .009" at 800 grains of 3F with eight balls 4" off the powder. The .45 cal. 13/16 burst into four pieces with a charge of 500 grains of 3F, five balls, 4" off the powder. The .45 cal 15/16 burst into four pieces charged with 800 grains of 3F, 5" off the powder. The 7/8 .50 cal burst into five pieces with the balls still inside loaded with 500 grains of 2F, and five balls 4" off the powder. The .54 cal 15/16" burst into two pieces with 500 grains of 2F, and five balls, 8" off the powder. The .58 cal 1" bulged .23" with 600 grains of 2F, and six balls, 12" off the powder. At 1500 gains of 2F, and fifteen balls 8" off the powder the .62 cal 1" barrel blew into seven pieces the the balls still inside.
The largest charges that did not damage these barrels with the balls seated on the power were, for the .36 cal 13/16, 200 grains and two balls. .45 cal 13/16" 400 grains and four balls. .45 cal 15/16" 600 grains and six balls. .50 cal 7/8" 500 grains of 2F and five balls. .54 cal 15/16" 700 grains of 2F and seven balls. .58 cal 1" 700 grains of 2F and seven balls...and the .62 cal 1" also managed 700 grains of 2F and seven balls with no damage.
The .54 cal 1" barrel was also tested repeatedly with 130 grains of 2F powder and a patched ball as the breach plug was unscrewed from eight to two treads holding the breach plug with no effect.
I've shared this information not to say black powder can't be dangerous, but these tests do convince me that we can shoot black powder rifles without great fear of them blowing up if we use reasonable caution.