Why not cast your own?--Part II

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Powderman

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OK, everyone read the safety precautions in Part I? Good. Now let’s go on to what you need to actually start casting.

1. Smelter (i.e., lead pot, kettle, etc.)

There is no law that says you have to buy an electric pot, or that you have to ladle pour. Each part has its benefits and disadvantages. The cheapest way to go by far is to get a cast iron pot, and a propane burner. The propane will last an amazingly long time, and the iron pot will last forever. If you go the iron route, get a small pot. One of these filled with alloy is amazingly heavy.

The best buy on the market for the bullet caster, IMHO, is the Lee Pro 20 lead pot. For about $70.00, you can’t beat it. It has all the features you need—a good pour mechanism, a thermostat, and a great price.

2. Small fan

This blows across the pot while you cast.

3. Protective clothing, goggles/safety glasses, shoes.

4. Molds.

The subject of molds has been discussed—and cussed about—more than any other single aspect of bullet casting. For it is the mold that has the final say in the manufacture of the bullet.

If you cast for rifles, you might consider a nose-pour mold. This makes sure that the base of the bullet is perfect, which is essential for accuracy. For handguns, you can use either. Again, the most economical molds are available from Lee in any configuration you might imagine.

5. A “beater†stick

Get a good hickory hammer handle, or even a rawhide or wooden mallet. This is to help get the bullets from the mold—more on this later.

6. A way to size and lube the bullets.

For the caster on the budget, again Lee gets the nod with a push through sizer that actually works quite well. For right at $110, you can get (IMHO) the best lubrisizer in existence—the Star, now made by Magma Engineering. The unique thing about the Star is that you can add on a bullet feeder, a collator, and an air handler to pressurize the lube.

7. A source for alloy

I use wheelweights purchased from a scrap metal yard, at about $40 for 150 pounds. Good and economical. I’ll talk about a way to save even more money later.

8. Flux.

When you cast lead alloy, you will notice that you have a lot of junk on the top of the melt. This is trash, to be sure—but it is also a good portion of the tin from your melt. Tin in bullets can be a good thing, as it is what makes bullets harder. Tin is also useful in getting the molded bullets to fill out. Adding flux to the melt does two things—it places the tin, antimony and lead back into solution, and makes the melt easier to pour. There are a few things that you can use for flux; however, the best thing I’ve found is Marvelux, by Brownell’s. This stuff works wonders. You can also use candle wax, or beeswax—but make darned sure you use it outdoors.

9. Miscelleaneous
You’ll need some towels, a padded box, or a coffee can with a towel and rubber bands. I’ll talk about that later.

Now that we have all of your stuff, it’s time to cast the bullets.

Continued with the next post…
 
When you cast lead alloy, you will notice that you have a lot of junk on the top of the melt. This is trash, to be sure—but it is also a good portion of the tin from your melt.

According to a rather extensive article in the latest Lyman cast bullet handbook, Tin does not separate from lead when it's molten. The only evidence anyone can point is 100% anecdotal. I forgot the name of the man who wrote the article on lead metallurgy, but he's won many awards for his work and appears to be very respected in the field. According to his article, the only way you can get it out is mechancal (centrifuge).

Fluxing is useful for one thing only, assisting in the collection of impurities that float to the surface of the melt and making it easier to remove them.

See this thread for more information on the subject. I attempted to contact the author, no luck.
 
Thanks for the link. I knew that beeswax and bullet lube made pretty good fluxes. I've used chunks of candle wax myself. Good stuff--but really smoky, and the fumes are flammable. Better cast outside!!
 
Sawdust is supposed to be a good flux as well... I remember casting with my dad on the kitchen stove ;-)

Yipe!!! :what:

I cast on the kitchen stove, too---ONCE.

The executive chef (read as: wife) made sure that there was NO doubt in my (at that time) military mind that on-the-stove casting would NEVER happen again. :uhoh: :uhoh:

The sawdust flux is interesting. Any idea of the chemical actions that take place to make it effective?
 
Bullet Casting

As an individual and top distributor of the founding Saeco cO. in California I have sold thousands of molds, hundreds of lead melting pots, have top dipped and bottom poured and operated 2 bulletmaster machines at 4,800 cast bullets an hour and owned a 3 ton lead smelter.

THE MOST EFFECTIVE AND ONLY FLUX I HAVE EVER RECOMMENDED IS CHEAP OLD ORDINARY CANDLE WAX!!.

With igniting any fumes or smoke from it in a room with a fan in the window blowing OUTSIDE.

NUFF SAID

JOHN PAUL
 
Hey folks,

I'm not a metalurgist, but I have been casting bullets for nearly forty years. Braindead stated that "Tin does not separate from lead when it's molten. " He also stated "Fluxing is useful for one thing only, assisting in the collection of impurities that float to the surface of the melt and making it easier to remove them."

I am not sure if Braindead is correct that tin does not work its way to the surface over time, but I am pretty sure that something more than dross comes to the surface. When I flux my mix (with plain old wax), it does have dirt or dross that is on the surface. In addition to the dross, there is also something on the surface that has a yellow or orange color to it. After dropping some wax on the surface, I allow the wax to catch on fire to consume some of the smoke, and I stir the alloy for a minute or two. As I stir the alloy, whatever it is on the surface that gives it the colored appearance is obviously returned to the alloy as a mixture, and the surface is left with a bright silver mirror like appearance - along with the dross which floats on top. Only after I stir the alloy to the point where I get the bright mirror surface do I then remove the dross from the surface.

At that point, I start casting bullets fairly quickly and can usually do about four pounds of bullets before the surface starts to show any sign of color on the top again. I then add more alloy ingots to the pot, let it get up to my casting temperature, then I do my fluxing and dross removal process and start a new round of casting.

Like I said earlier, I don't know if the colored substance on the surface is tin and/or antimony or not, but I am pretty sure it is some part of the lead/tin/antimony alloy that I do not want to remove if my intention is to cast hard bullets. I would also point out that I do not see the same colored surface when I am casting bullets with virgin lead, and I seem to notice it more when I am melting wiping solder with a high tin content. If that colored surface is not tin or antimony, I would be surprised.

Best wishes,
Dave Wile
 
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