Trying to hit a bunch of things at once.....
1) Placing tape across the slot in the fuel grain is only useful if the motor grain requires a spacer. None of the 24/40 F reloads (F12, F24, F39) requires a spacer.
2) The chances of lighting the delay only without igniting the propellant are slim and none. I am not saying that it couldn't possibly happen but I have never seen it.
3) What was the delay from the ignitor firing and the CATO? A delay grain burning all by itself burns at about 1/32" per second. With the motor burning, that jumps to about 3/32" per second. So if it was just the delay, it would burn for a long time before the ejection charge went off.
4) Blowing the aft closure out the back end and the motor case into the rocket is not something that happens when the ejection charge goes off. This is what happens when the aft closure comes off. Probably due to over pressure.
I have had only one CATO of a 24/40 motor (F39) and it was my fault. In hindsight, I installed an ignitor that had wires that were too large. They plugged the nozzle and it didn't like it at all.
It is possible that after the first CATO, the motor case will be more likely to spit the aft closure. The threads on the closure might have been worn slightly or the case might have expanded past its elastic limit and is now slightly larger than it used to be. Careful examination will show if this is a problem.
To help prevent this sort of CATO, do not use large ignitors in motors with small nozzle throats. Also, make sure that the nozzle is not resting on the blast deflector. Particularly if you have a red nozzle cap in place.