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Cast my second batch on Sunday, first batch with the new Lee 255 grain six cavity. I've weighed every one and have a lightest weight of 245 and heaviest of 255.6 How much variance is acceptable? Should the light ones go back in the pot?
I assume it's a pistol calibre mold? Either way if it's for plinking load and shoot. If your wanting more accuracy and consistency then separate them by weight. Pick the group with the most bullets in it for accuracy use then use the rest for plinking.
Try fluxing more often and stir the lead in the pot regularly. Also if you are using a gang mold you may have a cavity that is a bit light. Weigh each slug from the mold individually. Some guys use a hot plate to keep molds hot when adjusting your lead mix or fluxing. A cavity that is cooler than the others can throw a light slug.
Some molds have varying boolit weights, lee is one of them don't believe me try a NOE mold. There are little nuances as others mentioned. Alloy should be consistent.
Light ones should be culled there may be a void.
I look for nice sharp edges at the base and lube grooves, any rounded features should be culled as well they will measure light.
Be safe