Originally Posted by
PhilS
I'm afraid you're trying to reinvent a process that's been used forever and you're just going to get frustrated with the results. Dry chemicals milled together for a couple of hours (depending on your mill) is as good as you can get. When done, you should wind up with BP that feels like talcum powder between your fingers. It won't burn worth a hoot until you granulate it but to get good BP, it has to be milled.
Sulfur likes to clump even when dry but unless you dried it before milling, moisture is probably your problem.