Drvrage, no offense taken. Debate is good, and we may actually learn something. Let me state that I was talking about a choked barrel, not choke tubes. With choke tubes, by all means follow the manufacturers advice.
My post was written from my experience, but in order to add credibility to my point of view, I have just removed a Sellier & Bellot 2 3/4 inch 32 gram (1 1/8th oz.) Foster type slug from its shell, and have taken my calipers to it.
First let us agree that the nominal bore dimension of a 12 gauge shotgun is 0.729 inches. The actual dimension may vary from manufacturer to manufacturer, but 0.729 is 12 gauge.
Secondly, let us take for granted that a full choke barrel will rarely have more than 0.040 inches of constriction. You may argue for 0.045, but by the time you reach 0.050 inches of constriction, you start to "blow" the pattern.
Let us then look at the slug. It has a cylindrical centre section with ten angled vanes along its side (makes it a "rifled" slug) and a ring around its base just slightly greater in diameter than the vanes (the largest diameter of any part of the slug).
The diameter of the slug at its base is 0.740 inches, so already we have a problem - the base of the unfired slug is 0.011 inches larger than a nominal 12 gauge, and we haven't even reached the choke yet.
The base ring is only 0.102 inches deep, and the lead is soft enough to indent with your thumbnail. Clearly this ring is meant to deform and compress to the bore dimension.
Now let's look at the vanes. The diameter of the slug measured at the widest point from vane to vane is 0.728 inches, just less than a nominal 12 gauge. The vanes are 0.060 inches thick and should be more easily compressable than the base ring.
Finally, we measure the part that everyone is worried about, that solid central core. Measuring between the vanes at the top of the slug, the calipers show the diameter of the central core to be 0.640 inches. Measuring further down the slug (harder to do accurately with my calipers) I get a reading of up to 0.655 inches.
An 0.729 bore with an 0.040 constriction leaves an 0.689 hole for the slug to pass through. That central core is only 0.655 max.
It is my contention that the vanes and base ring of the slug will easily deform (compress) to the diameter of the barrel. Otherwise, why make the base ring oversize? The "solid" (it isn't, it has a hollow base) central core of the slug is small enough to pass through even the tightest of full choke barrels.
Perhaps it is the increased amount of compression of the vanes which make some Foster type slugs not shoot as accurately out of some fully choked barrels, I really do not know. What I do know now is that the slug is being deformed and compressed from the moment it is fired (unless you have a radically back bored shotgun). The slug, however, is not going to bulge or burst a barrel all on its own.
I suspect this sort of safety margin is also demanded by any slug manufacturers lawyers - fully choked shotguns are the most common, and to produce a product which would harm them would be to invite a never ending chain of lawsuits from unhappy customers (or their estates!).
I think the same logic applies to choke tubes as well, but always go with what the manufacturer says in this regard.
p.s. The instructor for my PAL course (nice fellow) told me that it was unsafe to shoot 2 3/4 inch shells out of a 3 inch chamber. That too, is false.
With all respect,
Sharptail