Campro bullet problems! Care to help?

Maybe I'm mistaken - Isn't there such a thing as "poor ignition"?

Yes, but not from a primer exploding slower than normal. If the primer isn't capable of producing enough heat that will lead to poor ignition. Magnum vs. standard for instance, Magnum primers typically provide a longer and/or hotter flame front to avoid hang-fires or duds.
 
Late to the party, but I also have a Henry Big Boy in 45 Colt and shoot Campro projectiles. I have only tried a few loads but based on my research Lyman is one of the few manuals to list 45 Colt rifle loads. The firearm Lyman used is a Winchester Model 94AE with 16" barrel.

For 250gr projectiles, they list Titegroup, W231, AA#5, Unique, Power Pistol, N340, 2400, IMR 4227, and 5744.

I tried Unique, Power Pistol, and 2400, and the best groups by far were with the Power Pistol. But... even at 100 yards, my group size is at least 4" (3-9X scope). Unique was very dirty and not accurate. 2400 was "clean" but 6-8" groups easily.

Lyman has the fastest load being 2400 (at 1236 ft/s) followed by AA#5 (at 1217 ft/s). OAL of 1.59"

With your powders (the only one listed was IMR 4227) they list 17.0 gr - 20.3 gr (WARNING! DO NOT USE - VERIFY) for velocities of 949 ft/s - 1198 ft/s/.
 
MV's just over the Sound Barrier will create accuracy issues at distance as the bullet slows down thru the Barrier.

I have no idea on the pressure a Henry or any other 45lc rifle will take. I do know if you ask Henry they will say it will shoot all 45lc SAMMI spec'd ammo.
Just for reference, 45lc Pistol Data for "Ruger, Freedom Arms & T/C Only", from Page 186, 2022 Hodgdon Annual

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One thing I read with 45 Colt (handguns) and modern smokeless powder is the powder position in the case. Read stories about people pointing their pistols "up" before leveling and shooting (to have the powder next to the primer) vs people pointing their pistols "down" before leveling and shooting (to have the powder next to the projectile).

I wonder if this is resulting in your velocity spread? Once you get your firearm back maybe try a string with the powder at the primer, and another string with the powder near the projectile, and see what happens? With the CAMPRO loads, my memory says the case is less than 1/4 full of powder.
 
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