While bullet casting can be a rewarding and cost-effective way to create custom bullets with a precision size and fit for the intended firearm, there are some common mistakes that beginners should be aware of. Below are some of the more common bullet casting mistakes and how to avoid them.
Not using proper safety equipment and practices
Bullet casting involves working with hot, molten metal, which can be dangerous if proper safety precautions are not taken. Before you begin bullet casting, make sure you have the proper safety equipment, including safety glasses, heat-resistant gloves, and a protective apron. You should also have a fire extinguisher nearby in case of accidents. If you plan to water-quench or water-drop your bullets to gain additional hardness, be very careful not to get any water in your lead pot. Dropping a wet bullet back into the melting pot can cause the water on that bullet to instantly convert into water vapor and cause a mini-explosion throwing molten lead everywhere.
Using the wrong alloy
The type of alloy you use for bullet casting will depend on the intended use of the bullet. For example, if you are casting hollow point or flat nose bullets for hunting, you may consider using a softer alloy to allow proper expansion. However, if you are wanting penetration (ie: bear loads), you will want to consider using a harder alloy that will penetrate without deforming. Generally speaking, rifle cartridges do better with harder alloys due to the higher pressures and velocities. Make sure you do your research and use the appropriate alloy for your intended use.
Overheating the metal alloy
Overheating the alloy can cause some of the metals within to oxidize, which can affect the alloy percentages and composition. This can lead to inconsistencies in the performance of the bullets. Make sure you keep an eye on the temperature of the molten metal and try to keep the temperatures as consistent as possible. Many people agree that the ideal temperature for bullet casting is around 700-760 degrees Fahrenheit depending on alloy and type of bullet being cast.
Rushing the process
Bullet casting can be a time-consuming process, but rushing it can lead to mistakes and poor quality bullets. If you cut the sprue too early, you can cause lead smears on your bullet mold that can create a galling of the mold surface. Also, when cutting the sprue too early, the bullet bases can suffer from tearing and voids in the bullet base. Take your time and try to keep up a consistent pace to make sure you make consistent bullets without tears and voids.
Failing to inspect the finished bullet
Once you have finished casting your bullets, it is important to inspect them carefully and cull the bad ones beginning the process of loading and shooting them. When culling, pay close attention and look for any defects, such as voids, wrinkles, cracks, rounded bases or rounded driving bands, and any other imperfections. Inconsistent bullets make for inconsistent performance down range. If a bullet has any of these imperfections, there is no need to worry or fret about it, just put it back in the pot (if it is dry) and recast.
Bottom line is: Consistent casting procedures lead to consistent cast bullets, which often allows you to have consistent results downrange! Take care, be safe, and happy casting!