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I had a G33J chuff like that once. I don't think it has anything to do with how long it was assembled. I assembled mine minutes before the flight. In my case it think I might not have gotten the igniter all the way to the top of the grain.

At least your flight still worked. When mine chuffed the 8 - 10 times, it only got about 30 - 40 ft up and the normally very stable rocket did a loop and the motor burned out. It landed a few feet from the pad and the ejection charge went off a second or two after landing. Fortunately it landed flat with no damage other then paint scratches and pride.
 
Did you sand the slot to remove any oxidation? The oxidation will prevent a thorough, fast ignition of the entire motor and I believe this can cause chuffing.
 
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