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silvercorvette and mrappe - yes, you guys, and me too, survived what many would today howl about being unsafe. Unfortunately, others didn't survive, and they aren't here to tell about it. Your survival, and mine, doesn't by any stretch of logic mean that it's actually ok to continue to intentionally pursue unsafe practices.
That being said, it's certainly possible to manufacture black powder safely. Understand the physics of the materials and the process and there's no reason why it can't be done safely and efficiently.
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