Posted 23 April 2004 - 04:39 PM
I sometimes use Plaster of Paris, which is basically the same thing as all purpose filler, to plug one end of tubes where I want to composition to be loose, such as salutes or inserts. I use clay for the first plug, as it is quicker and can be rammed against the bench, but for the second plug, on top of the powder, I use Plaster of Paris, hot melt glue, or a wooden plug. These, of course, do not need to be rammed or pressed. This is necessary as doing so would solidly compress the charge or crush the stars.
In the case of ground salutes, the paper shreds or splits, and the plaster/glue/wooden plugs remain intact, but they only ever seem to go a metre at most, and do not seem dangerous. However, as Matt said, hot melt is probably safer as it is less dense. The same applys to wooden plugs. Clay plugs tend to be destroyed, which is actually safer, as the dust produced isn't going to get very far at all. That is partly why clay is preferable where possible. Presumably they do the same in the air.
For larger aerial maroons the construction is much the same as star shells - cardboard discs held in place by pasted paper and spiking. However, for a quick, easy, and very low density 20mm diameter plug, half a wine bottle cork serves nicely.