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You should probably remove the barrel from the hopup from now on when testing your shots. First and foremost, preserving the integrity of the insides of your barrel is top priority.
What brand of BB's are you using? Wal-mart and bass-pro bb's will easily break and shatter on impact. I've never heard of them breaking inside the hop-up if they were reputable brands.
It sounds like you didn't assemble the hop-up correctly and the bb's are smashing into the barrel where the hop-up rubber is supposed to secure the bb.
Make sure there is no space to move inside the chamber where the bb sits. The bb should be firmly seated in the chamber.
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