This is not uncommon with dirty gold as you both have come to realize.
The short answer is that your gold is not very pure.
It is likely contaminated with silver and copper chlorides. At furnace temperatures these chlorides will decompose into the respective metal and metal oxides. These oxides and metals alloy with the gold and produce the crust upon cooling.
The problem is due to any one or all of the following.
1. Your solution was not properly filtered. The solutions must be 100% transparent with no particulate or cloudiness. Remember that diluting the acid auric chloride will cause nearly all silver chloride in solution to precipitate. This small amount of silver chloride has to be removed from the solution or it will end up in your gold powder.
2. You did not remove all of the base metals from the gold before it was dissolved. Your solutions should be yellow to deep orange red.
Any sign of blue or green is a strong indication of copper and or nickle contamination. Copper in the solution will precipitate as copper I chloride when an excess of SMB is used or if copper levels are very high.
3. You did not properly wash the precipitated gold powder. Here is a link to the washing technique:
Filterless wash process
This method is a slight variation of Harold's method and he deserves the credit for the process.
4. Your dish or torch induced the contamination. Always use a good clean dish to melt your metals. Always dedicate a dish to each type of metal (Gold, silver, etc.). Clean your dishes with molten soda ash.
To fix your nugget you will need to redissolve in AR and strictly follow the processes above.
Steve