Bullet Casting

I will have to admit, bullet casting has been my downfall. What I have been doing for years has worked, but it is time to learn more and cast better, more consistent bullets in order to try and improve accuracy at longer distances.

What I will be posting here will be details on the lead I will be using, the hardness and casting methods. For casting depth details, it will be best to search youtube, google or whatever other resources for your best results. The following will be what I do to suit my needs.

John Kort proved that the Lyman 427098 would perform well at longer ranges with black powder loads. He redesigned the 427098 by adding a large lube groove and a crimp groove. Accurate Molds made this mold for him, it is the 43-215C. 

I, as John, used the same concept but my change was to be used with smokeless powder Reloder 7 loads. I retained the small double lube groove of the 427098, but smoothed the transition from the forward driving band to the ogive as well as increasing the diameter to drop at .428". Accurate Molds made this mold and offers it as the 43-214A. This will drop a 214gr bullet from wheel weights, and can drop 220gr with a more pure lead mix.

John Kort used 50/50 pure/ww, which should be about 9-10 BNH. While Winchester advised using pure lead with black powder loads, some dissected Winchester 1914 smokeless loads tested at 10 BNH (may have hardened with age), and Mark Whyte preferred 9 BNH...and is what I used for the 40 shot target in 2019. Gel tested loads can be found here. After viewing the Gel Tests, click the Back To Bullet Casting tab to come back here.

Third Cast 18 August, 2026

With the new mix proving itself, and getting use to the single cavity steel mold...casting is underway! I have slowed down and making each cast count, better temp control on both the melt and the mold. The last 50 or so casts were great compared to the previous. Scroll down to the google sheets and look at the Third Cast Row

Second Cast 17 August, 2026

I was able to adjust some temps and get the estimated 93% Lead. 3.9% Antimony, 2.1 to 2.4% Tin to fill out pretty good. Still need to practice some more and try to make some improvements. I'd like to better replicate the weight variations from the example. Seven weights vs thirty five weights!! Below is the chart showing my results. I cut open some nice looking bullets that were too under weight. The below photo shows such void cavities that can make a long distance shot inaccurate. Find your mid range weight, and find out which weight is too light and why!                       ...the CHASE continues...

Two bullets of many that failed to reach the minimum weight, but looked good on the outside!

First Cast 14 August, 2026

Aside from previous cast, the updates below will be from current progress on trying to cast the best bullets possible.

My current lead is from the keel of a Catalina Capri 22 sail boat, which consist of the following;

• 96% lead, 4% Antimony, 0% Tin

• 10 to 11 BNH

The problem I am having is the sharp form on the bands and misc. flaws. Accuracy is still proven at 300 yards but...  The issue should be that there is no tin in the lead. Mixing the proper amount of tin should allow properly form bullets.

Problems;

• Surface Flaws, maybe internal flaws

• bands not filly filled

Obviously issues due to lack of heat and/or tin. 

Mold Issues;

Steel Mold - Single Cavity

• forms fine with high heat (50/1) but shrinks below desired diameter before crystalizing...needs tin!

Aluminum Mold - Large Two Cavity

• Unfortunately I purchased a large 45-70 two cavity block for the 44-40 bullets and the block is to large to retain the higher heat needed for precise lead flow...needs tin!

Antimony Issues;

• The 4% antimony already in the lead may prevent bullet expansion (for hunting) but should not affect obturation. 

So with that, I will be mixing tin with the lead to see if this improves in both molds.

The following cast bullet is what I have so far, the external flaws are evident. I feel if this were the smaller block, I would be casting sufficiant bullets. 

....more to follow!