No4 Enfield Severe Overpressure

Correct, I chronographed the first 10, then had 5 left to shoot a group to test the accuracy. Examining the rest of the cases, nothing abnormal can be seen. Ill post some photos tomorrow when I get the chance.
for sake of clarity, the velocities were as follows
24gr AA5744, Lyman 314299 Gas Checked, sized to .314.
1850 1835 1793 1827 1802 1825 1816 1842 1824 1839
 
Dacron is not a volumetric filler, it's a small wad that keeps the power at the end of the cartridge case allowing a more uniform burn, the rest of the case is empty.
 
No filler, not reccomended in the manual for that load, and fillers can cause their own host of issues on theri own.

Dacron is the same fiber they use in pillows.

Fills up the void in the case, while holding the powder against the primer flash hole, for even combustion.

It isn't tamped in tight. It's just pushed down inside, over the powder charge and expands to fill the void.

I usually just cut a bunch of 1cm squares, to push down inside the case.

Each square weighs less than a grain and unless you're using a very small case, will not have any effect on performance, other than to eliminate Kabooms or hang fires.

I mostly use Dacron with cartridges like the 50-70 or 577-450 or other large capacity black powder cases, when loading with smokeless powder.

Still, unless you were pointing your rifle downhill, and the powder was all at the base of the bullet, with your load, all that should have happened at a worst case scenario would be a misfire or hangfire.

That's why I'm thinking you somehow got a half charge or even less.
 
Can confirm rifle was loaded and fired from the bench, basically level to the targets. I do use Foam Backer rod as a filler in my large stuff like 577/450 and 577 snider as the cases are too big, even with black powder. The idea i though there though is to fill up the entrie air space as to not cause wave peak pressure and ring the chamber, or so i've been told. the issue presented to me with compressible fillers is that they can in rare cases slug up in the neck of the case and overpressure the round as well.
 
I understand that pure cotton, from cotton balls, works well.

No idea what sort of pressure occurred in the OP's rifle, but a catastrophic case failure can occur for reasons other than overpressure.
 
Maybe it's just me or my monitor, but in the 8th photo from the top in the OP's first post, it looks like there is a large (relatively-speaking) gap between the face of the receiver & the barrel shoulder and a matching gap between the end of the barrel & the inner receiver face. At both points, there should be zero gap. I am presuming, of course, that the photo was taken before the barrel was pulled & then partially re-installed one full turn short just for photos.

Given the above & the gross headspace issue that would cause, I find it interesting there was not a complete head separation, but rather just a primer / case-head blow-out.
 
From what I can tell from the pics the rifle is pretty much scrap I would never trust the bolt lugs or the receiver but that’s just me
 
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