Cast bullets 101

ben hunchak

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In the cast bullet business i get alot of questions on what works and at what price, and this is going to ruffle a few feathers, but a lifetime of casting and shooting cast bullets shows some trends, and this has to do with production(machine) cast bullet designs......Production casting machines require moulds that have very simple bullet designs, without sharp edges, fewest lube grooves possible, rounded corners, rounded lube grooves, bevel bases.....all these factors combine to allow the bullet to "drop" from moulds quickly without interruption to the machine(halting/slowing production)......These same factors combine to produce the LEAST effective bullets for the shooter!!!! Good cast bullets should have sharp edges, fore and aft., for max. shock(meplat) and for best gas seal of bullet base, bevel bases tend to direct gas along side of bullet. Bullets that have the most grooves tend to be the most accurate, combine this with deep square lube grooves and you have much more lube going for you. Production machines function best with only 1 alloy, which can be either too hard or too soft for your application, witness machine cast BPCR Slugs avail.(and at a good price) that are cast with Lyman #2 alloy(hard) and 1 lube groove....def. not what you want for BPCR bullets.......this was more of a primer for new users of cast bullets, and I will gladly answer(if I can) any questions re: casting/testing of bullets for the reloader.
 
I have been casting for about 6 years and have two casting questions. the first being that I have read that to be carefull not to skim off the tin with the dross. I understand why you would not want to do this but do not know how to tell if I was doing this.
Second is you see pic's of cast bullets with almost mirror shiny finish after being cast when most of mine come out almost a mat grey. If I keep the heat down they come out brighter but I wind up with more rejects from the cooler temps. I Use a lee bottom pour with properley cleaned ww. lead with about 6 oz. of tin added per 10 lb. lead for rifle bullets and straight ww. for pistol fluxed with Marflux. I have no issues with performence from this mixture and have been able to push lubed gas checked bullets out to 2400 fps with no leading issues.
 
If you flux before you skim anything off the top you will mix the alloy well, then you mix up alloy and introduce lots of oxy. by cupping air into ladle and mixing, lastly skim dross off the top. Here's a trick for bottom pour casters.....use plain unscented cat litter on top of melt, it acts as a flux and prevents dross accumulation and you can add alloy at any time! I prefer the ladle as I don't like the leakage of the bottom pour or the freeze up of spout! For freeze up, have a small propane or butane torch handy and apply heat directly to spout in case of freeze up.
 
Ben, I'm really impressed with the 325 grain WFNGC hard cast bullets you supplied me with for my .444 marlin. The crimp groove is super:D Really tenacious grip on the bullet with a roll crimp. I noticed that when seated on the crimp groove, the bullets don't feed easily through the loading gate, binding on the way in. Once in, they chamber and cycle properly, and are not engaged into the lands. Is this because of the wide meplat? I find that with a bit of fiddling they will go in the mag.
 
That bullet has a very large flat and it may be contacting the rear of the tubular mag. on the way in, if it is a problem let me know and you can try some 290 gr. LFN PB. AS long as the feeding into the chamber is good it is worth it to try these.....how do they shoot?
 
Been too busy with family and work commitments over the last little while to shoot it:( Hopefully that will change soon and I can sneak out :shotgun: I don't really want to try the 325 grain cast bullets at first until I can get comfortable handling and shooting the gun using 265 grain jacketed bullets. Those full-power cast loads pack a whallop:eek: and I would prefer to get that limbsaver installed before I start pummelling myself into a flinch:bangHead:

I'll definitely let you know how they shoot once I've tried 'em at the range!
 
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