Ok thanks. As for the shells - what would you suggest? Is it not ok to shoot 3" in this gun? The tungsten matrix are advertised as safe for fixed choke guns - like bismuth. I honestly have only shot maybe 10 or so through it anyhow.
And the other shells are lead (the one that I used yesterday)

I use those Winchester Longbeards. in a Remington 11-87 ,the shot load is encased in some sort of epoxy, you can cut open the shell and the shot will be one solid lump, I know that when fired it becomes a powder and buffer. I would shoot 1 1/2 oz max at 1200 fps or less. If that meant 2 3/4 " shells so be it. My self I would use 1 1/4 oz of 5 or 6 copper or nickel.

Another possible explanation could be the slight bulge and barrel split may have been caused by a phenomenon termed momentum -- too big of a load at too much velocity through too tight of a choke. These same catastrophic results could have occurred regardless whether lead, bismuth or tungsten loads were used.

First thing I would do after a blow up is to take the rest of the box of shells, weigh each one individually after assigning a number to each shell. Next, I would dismantle every other shell and weigh each component, leaving every other shell intact. I would keep all loads of powder in plastic bags for testing, to see if the powder is the powder that is supposed to be in that load. Next, I would take two of the shells and send them to Tom Armbrust for pressure testing. However, your blowup seems to be an obstruction.

How far back in your barrels is it to perfect, undamaged barrel?

I think a good welder could fix those barrels to be shootable again...might not be easy to hide the weld completely...and you can cut the barrels and have screw in chokes put in....some times these things just happen no way of knowing what went wrong... anyway good luck on the fix....charlie

I think you could cut it to 29", but probably best to go to 28". I suppose Briley would be the place?

Do you recommend anyone as a welder? Didn't really think this was possible. Looks don't really concern me as much on this gun.

Yeah I wondered about this - just never thought of it prior to this accident. Choke in that barrel was .032.

I don't think any good welder would want to put his name on a project like that ! If you know what I mean JMHO !