I recently had my original M1895 Winchester saddle ring carbine in 30-06 rebored/rechambered to 35 Whelen (prior owner had ruined barrel , apparently shooting corrosive stuff). Anyway, I've been working up loads , which I intended to be on the light side in deference to the age of the rifle and my shoulder. I shot a load with 49.0 grains of AA4064 and a 200 grain Sierra RN. The first shot was normal, hitting the target at point of aim. The second shot seemed to be a misfire. When I lowered the lever, most of the charge of UNBURNED powder blew out of the action. The bullet was stuck in the lead of the rifling and was easily bumped out with a rod. I'm a 30 year reloader, with probably 50,000 rounds under my belt; first time for this result. Cases were R-P once fired, CCI LR primers. I weigh each charge on a RCBS electronic scale. Clearly there was powder in the case, as a great deal blew out when the action was opened. I realize 49.0 is about 4 grain under the listed starting load; however, I have an old Hornady manual which lists 49.3 grains of IMR 4064 as a starting load. I might have expected this with a light load of a slower burning powder...but 4064? Any thoughts?