strenkarosa
The problem as I understand is one of ‘split’ casings. I offer this theory. If the drying phase of the recommended dry/smoke/cook instructions was by-passed perhaps this is what may have happened: The factory closed end of the casings is probably an excellent seal. The sausages were firmly stuffed then placed in the smoker without performing the drying phase. Say you did a leak proof closure seal that was enhanced by congealed sausage. Temperature control of a typical oven or smoker can fluxuate several degrees above a set point which could cause an increased internal vapor pressure inside a casing thus causing a split. The sausage was evidently not damaged and tasted good. Enjoy the fruits of your labor while making another batch.

strenkarosa
I have only made one batch of summer sausage also using an electric smoker. Your smoke/cook time seems to me to be excessively long. Did you follow the smoking/temperature steps recommended by Walton? What was the temperature of your sausages when you placed them in your smoker? My intent is to not be critical of your results but to begin an analysis of things that could have impacted your result. I am an amateur sausage maker with only a few batches made. I will follow along to see what we all can learn here.

applejack
This is the recipe I use for making homemade mayonnaise.
2 whole pasteurized eggs
1-1/2 cups canola oil. Almost any oil will make mayo. Do not use 100% extra virgin olive oil. You will not like the aftertaste.
2 tbsp 5% vinegar. I use a fruit vinegar. Red wine vinegar or apple cider vinegar or lemon juice works very well.
1/2 tsp salt
An immersion (stick) blender is a great tool.
Makes one pint
Put all the ingredients into a container that fits the blender. Blend on high speed. Almost like magic.
The use of an acid such as vinegar or citrus is the key to improving shelf life. Must be refrigerated. Cold ingredients form an emulsion easier.

Another suggestion to try brining. I have done chicken, turkey, and pork loin. I now will not smoke-cook chicken breasts any other way. I brined a turkey for last Thanksgiving and the result was amamazing. This was the best turkey I have ever cooked.

raider2119

I started making mayo about a year ago. I have used both unpasteurized and pasteurized eggs. I cannot speak to your basic questions but I get longer shelf life than a couple of days. I now use only pasteurized eggs and they are very easy to prepare. I use my sous vide water circulator for quick and positive temperature control for the pasteurizing process. My go to recipe uses only eggs, canola oil, fruit vinegar, and salt. I really enjoy the fresh taste of homemade mayo and now cannot tolerate the commercial brand that I thought was great stuff. Made more work for me but it is worth it.

Cali sausage guy
I am older than dirt but I am a newbie at making sausage. This is what my first attempt at packaging bulk sausage looks like. I used three pork butts in the batch and I had 23 pounds net product to go into the freezer. Most of that will be gifted to my Daughter and Grandson + great grandkiddos.

Austin

I have used an electric smoker for the past 15 years for brisket, ribs, pork butt , fish, and veggies.

This last week I made my first ever batch of summer sausage following the recipe and and supplies from Walton’s. This batch was 20 pounds when finished. Fantastic appearance and taste, I could not be more pleased.

Next up is a 25 pound batch of bulk breakfast sausage to go into 2 pound bags.