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How to Make a Lead Bullet

Casting your own bullets is a great way to lower ammunition costs. Lead is melted and poured into a mold, where it takes the shape of a bullet. The bullet is then loaded into a cartridge case and fired. After the initial investment of molds, dippers and a furnace, bullets can be cast nearly for free, using scrap lead that can be obtained several ways, including from automotive repair shops. Bullets must be cast either outdoors or in a well-ventilated garage.

Things You'll Need

Welding gloves
Eye protection
Scrap lead
Fan
Lead melting furnace
Wax
Metal spoon
Dipper
Bullet mold
Plastic mallet
Damp towel

Instructions

- 1
  Place the furnace on a table. Plug it in and turn it on. Set the temperature to high. Place a fan so it blows fresh air across the work area and away from where you are standing.
- 2
  Place the scrap lead in the furnace. The lead will melt in 20 to 30 minutes. Do not leave the furnace unattended.
- 3
  Put on the welding gloves. When the lead melts, use the metal spoon to scoop up debris, such as steel clips and non-lead weight material (zinc, steel, etc.) Remove the debris and place it in a separate metal tray to cool. This debris will be discarded.
- 4
  Shave off a thumbnail-sized sliver of wax into the molten lead. Use the spoon to stir the wax into the lead. The wax will attract dirt and other impurities in the lead and bring them to the surface in one floating clump. This is called fluxing. Spoon off the impurities and place them in the metal tray with the other debris. The wax fumes from fluxing may ignite. This is normal, so let the flame burn out on its own in the furnace. Repeat the fluxing procedure once or twice more until all impurities are taken out.
- 5
  Place the dipper into the molten lead and let it heat up. Place the mold on top of the furnace, with the mold blocks resting on the furnace's lip. This will preheat the mold blocks.
- 6
  Lift the dipper out of the molten lead. Turn the mold 90 degrees to the side, so the top of the mold is facing sideways. Bring the nipple of the dipper into contact with sprue hole, then turn the mold right-way up, keeping the dipper in contact with the hole. Let the lead flow into the mold, then slowly lift the dipper. Leave a small puddle of lead on top of the sprue plate (the sliding plate that covers the top of the mold). As the lead cools in the mold, the lead will shrink a little, and it can draw from this extra lead reserve.
- 7
  Use the plastic mallet to whack the sprue plate open. The sprue plate will swing away, cutting off the base of the bullet, leaving a sharp, well-defined bullet base. Dump the excess, cooled lead from the top of the sprue plate back into the furnace.
- 8
  Walk over to a folded, damp towel and open the mold's handles. The bullet will drop from the mold onto the damp towel. The damp towel helps cool and cushion the falling bullet so it will not deform. If the bullet does not fall freely from the mold, lightly tap the mold handle's hinge with the mallet. Never strike the mold blocks themselves.

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