
ive had the same thing happen! i was putting it down to too much moisture in the sand.i was having a lot of these type of things happen till i changed my sand management system. i was trying to keep all of my sand "just right" a larger hobby foundry i know of keeps their sand moist ready to use. i started to but as my sand increased it started to become quite a task. i now completely dry my sand ,run it through a sift and just wet up enough for what i want as i want. i discovered this by trial and error! i was given a book on casting in the backyard written in 1978 reprinted 1980,1982,1997. only a couple of days ago. in the book it outlines this practice as the best for backyarders!!! ( the backyard foundry by b.terry aspin. )