Well, nothing like waking up the board... So a few general comments after reading the responses.
Thanks for the comments regarding stupidity... those were really enlightening. As I do believe I mentioned, I wouldn't be doing this without my strain gauge setup in place, and while I hope it would be obvious, the rifle would be bagged and I wouldn't be anywheres near it when I pulled the string. I have my own range on my place, so those who assume I would be doing this at a public range can relax now.
Quite aside from reloading/casting/shooting, during my adult life I've been a miner, blast hole loader, commercial diver, and paratrooper. I have yet to spend a day in the hospital and never had an accident in those occupations.
Some of you may assume I'm stupid, I prefer to believe I put a lot of thought and planning into anything I'm considering doing that may be risky in any ways. That includes asking groups of people if they know of anyone who has done this kind of thing - by which I mean approaching it with some kind of plan and precautions, not just dumped a a full measure of powder down the barrel. And lots of interesting projects have been put aside because I thought hazards were unmanageable, by the way.
Why would I do it? Because I'm curious, because I've been experimenting with firearms for 40 years now, because it might be useful. Some people are into the whole era of black powder: the rendezvous, dressing in period clothing, nothing but authentic gear. Some are possibly into competition. Some because black powder seasons extend their hunting season. Some because they just plain like it. Some, of course, a combination of the above. Well, technical issues and questions intrigue me, and always have.
One thing I have found over time is conventional wisdom is usually pretty much right. On the other hand, sometimes it is bogus: you're not supposed to be able to fire high velocity cast bullet loads without badly leading your barrel and losing all accuracy. But then Tom Slater comes along and wins cast bullet benchrest competitions with cast bullets doing 2800 fps+ and group scores well below .5 moa.
And wait a minute... I'm sure most of us remember the conventional wisdom that "you can't overload a black powder rifle, the excess just goes out the end of the barrel". 30 years later, that has sort of changed...
Do I respect Green Mountain's engineering? Certainly. On the other hand, there is the little matter of legal liability and due diligence here. Not to mention that the far more likely scenario is somebody pouring 60 grains or so of rifle or pistol smokeless into one of their barrels. Even if somebody using pressure test equipment developed a "basement load" that developed no more than, say, 16,000 psi (just to use some numbers), could Green Mountain (or any other barrel maker) put anything other than "Black Powder Only" on their barrels? Not hardly.
I'm not interested in in-lines (although they are perfectly legal for hunting here and have pretty much eliminated traditional designs in this area). But then again, I'm not interested in learning to knapp flints, make a set of mocassins, etc.
That should deal with the why and background. I'm not trying to justify the "why" regarding my interest in technical issues any more than you will see me ask anyone to justify the "why" of staying with period correct firearms and acountrements.
Anyways, with the drama out of the way, it's clear that nobody has heard of anyone investigating this with a pressure recording setup. But some interesting comments did come up that were technically interesting.
The first was the strength of the sidelock design in general, along with the nipple. In one of the other threads, it was pointed out that some loads published by Lyman are in the 26,000 psi range. I don't have that newer Lyman manual, but I think it is safe to assume Lyman feels that load is safe to publish whether the reader is using a rifle with a Spanish barrel, or a rifle with a Green Mountain barrel.
Switching over to the smokeless side of things, I load a 93 grain wadcutter in my .32 H&R with 3.0 grains of Unique. Hogden says that it takes 4.0 grains to develop 19,000 psi. Certainly, much less than the 26,000 psi generated by the published Lyman black powder load.
So... putting that same load in a .32 muzzleloader... what would change the dynamics enough to turn a load that generates less than 19,000 psi in a hangun (which is not enclosed by a breech, incidentally), to one that develops more than 26,000 psi?
Black and smokeless powders do burn differently, obviously. Now... my .32 wadcutter loads have a very light crimp as that's where I get my best accuracy. I really can't say how that relates to the resistance created by a patched ball seated on top of the powder charge. That is a definite unknown.
Anyways, where and why the dynamics would differ is of interest to me, and I will investigate it once I pony up and purchase the pressure test equipment that is mandatory for anything like this.
For those interested in things like chronographs, pressure trace equipment, etc, here's a link:
CED pressure test software/hardware