Diver:
You’re not the only one.
I used to make solid fuel rocket engines (not terribly good ones) when I was younger by melting the saltpeter and sugar together, then casting them. I found they burned faster this way.
I did a few safety tests first, putting some on tinfoil and a cookie sheet in the oven with a thermometer, to see when it would spontenously ignite, and it melted, bubbled for a minute or two, and didn’t burn, up to a hundred (F) hotter than melting, so I felt fairly safe. I also lit off a bowl full (as much as I’d be working with) to see what it would do. Both experiments showed it to be fairly safe, and with a fairly low yeild if I was careful.
So I mixed the SP and Sugar, shook them together in a plastic jar, and then poured them into a metal pot and slowly increased the temperature, stirring with an old wooden spoon (after the chopstick incident, which was funny, in retrospect) until molten, then quickly poured them into molds.
I seem to remember using a double boiler to remove the potential for hotspots… can’t remember if that worked, or if I simply used a thick-bottom pot.
Anyways, if worked fairly well. I’d rig a funnel out of a magazine subscription card, pour the mix into a cardboard tube and put a safety fuse (the stuff guaranteed to burn at a set speed) in the mix so it hardened around the fuse.
One problem with this is that the mixture wants to boil just above the melting point, and it’s nearly impossible to get rid of the bubbles. Needless to say, the foam isn’t as effective as solid fuel is.
Fun experiment, and I think, fairly safe. I was always anal about personal safety, trying something only after trying to make it blow up in testing, so see where the limits were.