Hi,
I have just read some of the recommendations for bullet casting and some of them are misleading.
Use only pure lead for casting muzzleloading bullets. You do not need to use beeswax when you are doing this.
The only time you use beeswax when casting bullets is if you are casting bullets for centrefire firearms. Centrefire bullets have to be hard so tin is used in the melt to harden the lead. The tin seperates out and beeswax is used as a flux to pull the tin back into the alloy.
The lead in a muzzloader has to be soft so it can engage the rifling. If you are using a hollow based bullet, (Minnie)? the charge blows the skirt outwards so it grips the rifling. If you have the slightest amount of tin in the melt it will stop the skirt expanding and you will not get any accuracy.
Revolvers also need pure lead because the bullets is forced into the rifling to engage it.
A small amount of tin in a patched ball firearm is ok, it is the patch that grips the rifling, not the lead.
Lead flashing, airgun pellets, water pipe and gas pipe are all ok for casting muzzleloading bullets. I have done a drop test on balls cast with these and then measured them with a micrometer and they all come out the same.
Lead flashing and water pipe tend to be corroded/oxidised by the time we get it so a lot of scum comes off it. Don't worry, once this has been removed the lead will be clean.
New flashing has, I believe, zinc in it and is not suitable for casting bullets.
Wheel weights are no longer made from lead, I think these are zinc also, don't use them the metal is too hard.
If you have lead pipe with a joint soldered on remove it before melting the lead. Solder has a high tin content and will contaminate the melt.
Before you start casting bullets/balls wash the mould off with lighter fuel to remove the grease or oil. Then, "smoke the mould". To do this use a match
to put a coating of soot on the inside of the mould. This stops the bullets coming out wrinkly and gives them a smooth finish. You only need to do this once and you can cast a few thousand bullets without having to "smoke it" again, although you can re-do the mould if you think you need to.
Don't use a candle, the soot is greasy and will spoil the finish of the bullets and defeats the object of "smoking the mould".
NEW ADDRESS FOR HSE RCA DOCUMENT:-
Health & Safety Executive,
Explosives Inspectorate,
1.2 Redgrave Court,
Merton Road,
Bootle,
Mersyside, L20 7HS.
Tel-0151 951 3775
Explosives.licensing@hse.gsi.gov.uk
I hope this has been helpful. Good luck with your casting.
Steve W