Well Steve, it happened to me. I was loading a listed starting load of Winchester 760 in a neck-sized once fired 3006 with a 165 grain bullet seated as far out in the case as I could. The first round was a bit soft but I expected less than maximum recoil with a starting load. The bullet hit the target jut about dead center - next shot went puff....... and then BOOM. The case was badly deformed with the head extruded to larger than normal, case body was bulged and the primer pocket was so big the primer was destroyed. After recovering from the shot I checked my gun and it seemed unharmed but I packed up and went to the gunsmith to have everything checked out. The weapon was fine - a Remington made 03A3 - and the only explaination was a "delayed detonation" from powder that was ignited poorly over a large surface area. In using low powder densities I always put the bullet to the OAL specified in the book.
PaulS
Well I've told this story before but this seems a good time to tell it again. I was loading for a Winchester M-100 auto in .308 with 150 grain bullets and the only suitable powder I had was Hodgdon's H-414, same as Winchester 760. That is not an entirely suitable powder for 150 grain bullets in the .308 since 50 grains is all you can get in the case and my Lyman #47 manual lists that as producing only 37,500 CUP, well below standard operating pressure for the .308. I first loaded five rounds each with 47, 48, 49 and 50 grains. Fired all of those and pressures did seem very mild just as the Lyman book had predicted. I got the best group with 48 grains so I loaded the same 20 cases all with 48 grains and returned to the range within an hour. I was shooting prone and on the eighth shot I thought something sounded odd and thought I had caught a puff of smoke in my peripheral vision. I glanced to the right where the semi-auto was tossing brass and there was one case with a gaping black hole where the primer should have been. The case head was grossly distorted but the rifle was OK.
Now when I tell this tale people want to explain it away. "Too much powder", no, the case won't hold enough of that powder to produce even normal pressure, no way you can overload with H-414 behind a 150 grain .308. "The wrong powder", no, I dropped all loads from the same powder measure, how could one case out of forty get the wrong powder. "soft case head", no, that case had been previously loaded with a similar or heavier load and the primer pocket was still tight. "Deep seated bullet", well it was a semi-auto rifle but it was also a compressed powder charge, not likely that the bullet could have been driven much deeper into the case in feeding.
I do understand why people are reluctant to believe anything could go wrong with a load listed in a good manual but in this case it sure did. Normally that load would have produced only about 30,000 CUP and I believe that is borderline minimum pressure for H-414 or W-760 powders to burn properly and S.E.E. seems the likely explanation. Years later I had a similar experience with what should have been a mild load of H-414 in a Remington M-600 .243. It has been said that investigations have always concluded "reloader error". The truth is that very few of such incidents are ever "investigated" at all and if they do investigate and come up with no conclusion at all, then "reloader error" is the quick and easy answer. Don't believe it if you don't want to but I'm certain it can happen. We just don't know so much about how smokeles powder actually behaves as we may wish we knew.