I posted a variation of this over on the "British Miltaria" Forum and thought you might find it interesting.
Here's another option for the cheapskate and/or guy who likes a challenge. With this process you can make a wide variety of molds with nothing more than drills and taps, using old (and cheap) Lee molds, and a bolt you can buy from the hardware store. Here's what I did:
1.
Make the Mold - Drill out an old Lee Mold (I used a 9mm double mold) with a 37/64" drill. This happens to be my Cadet Carbine's bore size (0.578"), so the untapped part will "ride the bore". Tap the mold to your desired depth with a 5/8" NC bottoming tap. This will create sharply pointed grooves to a 0.625" depth in the mold;
3.
Make a Sizer - drill a 1 1/4 NF bolt in stages to 15mm, then cut it off to about 1 1/2". 15mm = 0.5906. Which is about 0.003" greater than my groove size (perfect for cast bullets). I have since polished out the ugliness shown.
4.
Cast Some Bullets - get the Alloy and Mold HOT! The narrow pointy grooves are tougher than usual to fill. I applied Lee Alox Lube.
5.
Size the Bullets - same process as for the Lee sizers. Borrow a large sizing "pin" from another sizer kit, and run them through.
6.
Load and Shoot
My mold produces bullets as shown that weigh a sized and lubed ~480gr when cast from wheelweights, and are ~0.725" long, so stabilize nicely in the slow twist of my Cadet Carbine. Yes - I could just buy a 0.590" mold and save the effort, and yes, the bolt, old mold, tap and drills cost something (and the drills are a bit difficult to find), but I made my own custom mold and can apply the process to other bore sizes that match available taps such as the 5/16" (0.312"). The spiral, continuous lube grooves are an oddity, but holds the lube well and the accuracy seems unchanged (this is not a MOA gun).
Are you going to try the Maxi's next? Sounds like pretty darn good results as it is thou.
