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I would simply NOT make black powder. I would make a different product with same ingredients except leave out sulfur. Sulfur is the demon in the triple mix that renders it so unstable and easily ignitable -- properties you simply don't need if you use a percussion lock/primer, or if you anyway pour a separate FFFG triple ingredient blackpowder into the pan of your flintlock. Sulfur also makes most of the smoke. Losing all those disadvantages is worth that 10% power drop incurred by not using sulfur.
Black powder without the sulphur and less smoke? What an abhorrent notion
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