Metal Bullet Casting

Casting bullets continues to survive in an era of reasonably priced, factory-made standard ammunition for a variety of reasons. Some shooters prefer to make their own ammunition, while others are using firearms that require modified ammunition. Finally, there are those with antique or reproduction firearms for which bullets simply aren't made.

Identification

Casting is the process by which a liquid is poured into a mold and allowed to solidify. The mold is then struck and the casting removed. For bullets, this almost always involves the use of molten iron, lead, or an alloy based on these metals.

Warning

Casting bullets is dangerous work. There are the obvious dangers of working with molten metal, but also lead (commonly used in making bullets) is known to cause birth defects and cancer. Always work outside or in a very well-ventilated area. Wear safety goggles or glasses. Wash your hands thorough before eating, drinking or smoking if you have been casting lead bullets.

Function

Casting a bullet starts by cleaning the mold for residue from previous castings, and then smoking it. This puts a layer of soot in the mold that will help with striking it and removing the bullets. A typical bullet mold will actually allow for several bullets to be cast at once, and may have a hinge to open it. That hinge should be kept well-lubricated. Lead has a lower melting point than iron, and is also heavier and softer. That is why it has always been so popular for bullet-making. Once the metal is molten, a layer of slag will inevitably form at the top and this should be skimmed off. All other liquids should be kept way from the molten metal--sprinkling water on the molten metal will cause bits of it to spatter everywhere and this is an extreme safety hazard. The metal is poured into the mold, allowed just enough time to turn solid, but not to fully harden and then struck from the mold and broken out as bullets.

Significance

There are a variety of reasons for casting bullets at home. One is saving money. Once the equipment for reloading ammunition has been purchased, avid shooters who use a lot of ammunition find that reusing their brass cartridges and making their own bullets is cheaper. The lead can certainly be acquired easily enough at any scrapyard. Another reason are muzzle loader enthusiasts, who find that making their own bullets is either part of their desired historical experience or getting manufactured bullets is simply too expensive. There are modern firearms that require either modified or homemade ammunition, such as the famous .44 Automag pistol; ammunition is no longer made for this, so new ammunition must be made by modifying a .308 Winchester casing and loading that with a new bullet.

History

Factory-made, standardized ammunition is actually a relatively modern phenomenon. Prior to the mid-nineteenth century, it was common for firearms to be made and sold with their own bullet molds, since the barrels were far from standardized and two guns with the same calibers might fit slightly different bullets. This was especially the case for old muzzle loading rifles, which had more demanding tolerances over their smoothbore counterparts.