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I thought about recoil possibly allowing the projectile to slip out of the sabot.
One solution would be to have a semi-circular groove turned in the side of the projectile, with a matching rounded rib on the inside of the sabot. When the sabot was crimped in the case, it would grip the groove in the projectile.
Of course now the projectile just got more complicated and thus more expensive.
Another thought was they sell knurled dowel pins. This might give enough texture for the sabot walls to bite into, but I don't know what this would do to the aerodynamics of the projectile.
Of course the point is now basically moot since all of the desirable replacement materials are outlawed. I suppose you might make them out of copper - beryllium copper is banned but not pure copper, but I imagine that is more expensive than lead.
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