I wear ear/eye pro when shooting flintlocks at the range, but not while hunting with them. Knock on wood, no issues at this point.

It did mess up the back of my left hand when I leaned over a straw bale with my flintlock and put my arm under it like a I would with a modern rifle to get it up high enough to get on target, and didn't stop to think about the pan discharge. Wow did that sting, and I had a visual reminder of that stupidity for about 10 years every time I saw the faint grey spots in my skin from the flecks of powder (they have faded since, but it was an interesting thing to have when I was in college, let me tell you...)