I've been having good results with Pyrodex and Estes ignitors potted into cardboard tubes with epoxy:
(Click to enlarge)
The tubes come from 1/4" launch lugs from Apogee. For larger charges, you could substitute 13mm body tubes to keep them shorter. I haven't tried that myself, yet, because all of my rockets are small. The charges in the picture were tested as follows:
1/2" charge in a Blue Ninja with a piston and a sealed bulkhead: perfect ground test
1/2" charge in the same Blue Ninja with a hole in the bulkhead and another in the piston: Partial ejection (lesson learned: Pay attention to pressure leaks)
3/4" charge in a Thunderbolt 38 with a piston: partial ejection in ground test
1" long charge in a Thunderbolt 38 ground test: adequate ejection, but a little wimpy.
All tests and flights burned the pyrodex completely.
Then I made a second batch, with one launch lug yielding two 1.25" charges and one 1/2" charge. Two of the 1.25" charges worked perfectly yesterday in my level 1 and level 2 cert flights, in glorious mid-70's weather. Today it's 50 degrees colder, snowing, and blowing like crazy, so it must be springtime in the Rockies.
In case the construction method isn't self-explanatory from the pictures, here are some details:
1. Cut your tubes in lengths appropriate for your rocket(s) based on ground tests
2. Carefully bend up the tips of the ignitors so that the ignitor head will be in the middle of the tube while the rest of the ignitor is laying flat
3. Mix up some 5-minute Epoxy and glop some onto some plastic or waxed paper. Set the ignitors into the epoxy, making sure that the leads are completely embedded and the head stays dry. To make them easier to separate later, keep them in a line, and some distance apart from each other.
4. Put the cardboard tubes over the ignitor heads, doing a little twist to make sure the epoxy adheres to the edge of the tubes all the way around. Wait for the epoxy to cure.
5. Fill up the tubes with Pyrodex or BP. Tamp down gently so the powder leaves the top edge exposed all the way around.
6. Mix up another batch of epoxy and cover the ends of the tubes, making sure that the epoxy adheres to the sides of the tube all the way around the top.
Time to make a batch of 6 charges: 10 minutes + waiting for cure + 5 minutes
Cost: $5.00 for 6 ignitors + $0.10 for powder + ~$1 Epoxy