Well, that certainly is a dissapointment and I’m sorry to hear of the failures. In all of my use with BOSS offerings I cannot say I have had a single issue that was ammunition caused, outside of two 3” 12ga hulls that failed to eject due to it splitting at firing, which I have had occur with every brand of ammunition and hull type at some point, so it was credited as a “you shoot enough you will see a failure” event in my mind. I have used the 10, 12, and 28ga offerings for several seasons now and not suffered from any primer issues.
I have read and heard of hard primer issues, and I don’t discredit them. Some of it is certainly a combination of a harder primer and a weaker hammer spring, dirty gun, etc., and some of it is sure to be an issue with the primer itself. The approach that BOSS takes with recommending that the shotgun be evaluated, cleaned, and or re-sprung is simply due to the fact many folks allow their shotguns to fall into disrepair and there are a lot of tired action and hammer springs out there. I have resolved my fair share of issues in shotguns with spring replacements and chamber servicing, both often forgotten or neglected servicing points on old and new shotguns alike. So, does it make you happy when you properly care for your tools and are told that lack of maintenance is your problem? Nope, sure doesn’t. That’s when being persistent, polite, and patient in working with them becomes critical. I have had amazing customer service experience with BOSS, but they are still people, so they will have failures.
Boss is using Ched hulls and primers, and Cheddite is not necessarily known to be the absolute highest quality, which is reflected in their more economical price which is passed on to Boss’ customer (especially when compared to other bismuth offerings). Consider as well BOSS has elected to load their 12 and 20ga ammunition with the magnum or “hot” Ched primer and this seems to have been a larger cause of “light strikes” than prior to their change. It improved the reliability of ignition in cold temps, but did increase the number of issues with light struck primers.
The thing is, when you turn out millions of rounds of ammunition a year you are bound to have some duds fall through the cracks; regardless if you are a large or small manufacturer. Most companies accept a 1-2% “lemon” rate in their manufacturing. Times that by millions and it’s a big enough number to seem like a big problem.
It’s difficult to import a hull with an existing primer and have any control over the QA/QC of the primers loaded in those hulls, and with little to no availability of US or Canada made primers that are not made and devoured by the large manufacturers, it is next to impossible to keep that aspect in house without terribly increasing price. It’s a catch-22 to be honest.
Many will claim that they have never had an issue with the big manufacturers, but I will say then they just have been fortunate, because I and others have. It’s kind of the luck of the draw. Dud primers, split hulls, failed wads, bloopers, squibs, stuck hulls, bad patterns, poor shot quality, etc. I’ve seen it happen with the cheap loads and the “premium” ones. I can say certain manufacturers such as Estate and Kent have been my worst experiences, but I’ve seen plenty of problems out of Winchester, Remington and Federal as well in cheap target and premium hunting loads alike.
if you are really unhappy with the loads and do not want to give a newer lot a try, I would recommend either giving Boss’ customer service one more try or just selling them off. Someone will want them.