Casting Balls - What do I need?

[stormcrow]

It’s time I started casting my own roundballs and looking for advice on where to start. I have read here that it is easy, but also have seen references to scales, fluxing, hard and soft lead, etc. I want to do it right, but the question is what all do I need to get set up for this? Will plumber’s lead suffice for material? Where can I find the best tutorial on how to do this properly, including any safety precautions?

Thanks much!

 

[ohio ramrod]

You really only need three things, heat source/container, mold and lead. Many prefer a gas stove with pan and use a laddle (dipper ) but I prefer an electric pot for even temperature control. Lead pipe or flashing is a common recycled source of lead but some use wheel weights. The main thing to remember is ventilation.Lee molds are reasonable priced and work well but they are aluminum and require carefull handleing. Lyman are cast iron and are more rugged. A lee melting pot & mold can be purchased new for around $75.00. Recycled lead for around 75 cents a lb. But often found free if you look around. :idunno:

 

[Sunkmanitu Tanka]

I have a small melting pot that I put onto the cookingfire. A laddle to scoop the molten lead. A wooden stick to open the bullet mold and the mold itself. I wear a long sleeved shirt and trousers and something on my feet to protect myself from splashes of hot lead, or from a hot ball that faals in the wrong place (hasn't happened yet, but better safe than sory!).. I flux the molten lead with some beeswax if necessary, and scoop off the dross with an old spoon. All this I learned on this forum. It saved me a heap off money and as a surplus: my balls are far more equal in weight then the store bought! To top it off ... it's fun to do!

 

[mooman76]

I started out with a coleman stove and a cast iron pot and a home made ladle. Worked fine. A regular stove will work too or a turkey fryer set up or a electric hot plate if it gets hot enough. I now use a Lee electric pot for the convienance. I still like ladle cast. Lee mould work fine as long as you treat them good. There are some videos on Utube.

 

[Lonegun1894]

My first few were done using a old pot on the kitchen stove for a container/heat source, a Lee mold, and an old spoon for a ladle. Now I've grown up and become a little more safety conscious so use a Lee melting pot out on the back porch (ventilation, ventilation, and did the guys above mentione ventilation?), a ladle, and still use mostly Lee molds. As to protective clothing, I can show anyone who wants to drive over a scar on my side to show what happens when you cast in nothing but boxers and lead splashes on your skin. I'll give you a hint, the skin peels off when you remove the lead. So I HIGHLY recommend at least something to cover any sensitive areas you dont want burned, and eye protection. Cause I know if it had gotten in my eyes, I'd be blind. The scar on my side was just a good lesson and a permanent reminder of the fact that stupid hurts, and it did. Having said that, this is something that can be done very safely if you just follow the basic safety precautions.

Protective clothing (glasses, gloves, long sleeved shirt and long pants, and closed toe shoes), ventilation, no kids or pets to knock anything over, and no water anywhere near the melted lead as it can cause an exciting splatter reaction which will make you really appreciate that you wore the long sleeves, pants, etc. A little common sense goes a long way to keep you safe. I say go for it and get started casting, cause it will make your shooting quite a bit cheaper and make you able to make your own instead of relying on what the local store has on the shelf.

 

[damron]

I 2nd ohioramrods advice

george

 

[ken.clements]

It’s time I started casting my own roundballs and looking for advice on where to start. I have read here that it is easy, but also have seen references to scales, fluxing, hard and soft lead, etc. I want to do it right, but the question is what all do I need to get set up for this? Will plumber’s lead suffice for material? Where can I find the best tutorial on how to do this properly, including any safety precautions?

Thanks much!

Some very good advice up above

I pour in my cellar; behind closed doors (nobody bothers me).
I use a gas flame with a powerful kitchen exhaust hood. I don’t flux, all the junk swims to the top when I stir the pot. Scoop that off.
I knock out the freshly poured Minie’s on a thick piece of cotton cloth to not damage them.
When the pot is almost empty, I carefully put in more lead. I look at the Minie’s I’ve already poured and the ones with ripples (mould not hot enough) go back into the pot.

Here are some tips:

Ripples or waves in the ball / Minie = mould not hot enough. Either heat up the mould in that you dip the corner of it (do not do this with a aluminium mould!) in the hot lead (2-3 min) or you take your time opening the mould (the first 10-15 balls are going to go back into the pot) so that the hot lead stays longer in the mould (to heat it up)
When heating the lead in a cast iron melting pot (what I use) with gas, adjust the flame and stand away until the lead is completely melted in the pot”¦
Rainbow colours in the lead in the pot = lead too hot
Do not wear skin tight rubber gloves = you cannot get them off fast enough (experience), and rubber melts”¦ I don’t wear any because the danger is (for me) to big that I get hung up with the cuffs of the gloves
Work boots = trust me ”¦ experience
Cotton clothing = cotton doesn’t melt
Glasses = only have two eyes

Its going to take a couple of times to get it where to you are happy with the results, practice makes perfect”¦when you get everything up and running 200 ”“ 300 balls / minies in a couple of hours should be the norm

 

[hthomso]

I pretty much have to agree with Lonegun. I still use the Lee Precision melter and moulds. I can't stress enough the safety aspects. I cast in my open garage with a box fan drawing the fumes away from the pot. Always wear long pants and SHOES. Gloves and safety glasses are a must in my book. All you have to do is get some of that molten lead on you one time and you are a believer. Luckily, I have only one experience with the lead contacting bear skin, and it was minor (foot). Don't become complacent around molten metal.

 

[MSW]

the advice here is good.

I use a lee pot, and although some folks have trouble with the bottom pour, I've had good results so far. These pots can be had used, but that can be something of a crapshoot. If you take reasonable care of the mold, it will last you the rest of your life- just don't strike it with anything metal (if you must whack it, use a bit of broom handle or a re- split piece of firewood.)

You should cast in the open, with good ventilation, wearing long sleeves and long pants and closed toed shoes. I wear my glasses- not only to protect my eyes but to correct my vision, which has deteriorated in recent years. I wear heavy leather gloves out of habit.

Of course, don't eat, drink or smoke while you're casting (you probably won't have time). And be sure to thoroughly wash your hands when you're done... they'll be funky from the gloves, so you'd do that anyway.

'Running ball' is (IMHO) a really relaxing way to blow off a few hours, and it helps you make good smoke!

 

[necchi]

Just put "casting" in to the search option in the blue bar above, click the little box for
"this forum only" and you'll find enough info, experiance and advice to write a book,
:haha:

It's good advice to do this alone or away from folks.
I was casting last weekend and a neihbor stopped by visiting, I caught my self being a little inattentive.
A bystander watching doesn't bother, but the conversation was distracting.
I stopped, turned the fire low till he left.

 

[Sunkmanitu Tanka]

How did you get that molten lead onto that bear's foot??

Sorry - just couldn't resist it :haha:

 

[damron]

i cast in shorts and no shoes in the summer.No kidding.I dont wear gloves either and do all of my mold manipulation with a stick and spoon.Just no water near your pot as others have said..Just wash your hands with good soap and hot water after casting as that how you ingest lead.It aint gonna become airborn at the temperature lead pot heats it to.

 

[Rod Lassey]

It can be as expensive or as cheap as you want it to be. Really, the only expensive item is the mold, the rest can usually be cobbled up from around the house or shop. For some years, I used an old cast iron frying pan, and large spoon.

I approach casting a little differently, as I'm pretty much interested in historical aspect. I do all my casting around a campfire--takes a bit longer to melt, but a wood fire will get hot enough to work just fine. I use a dipper (original hand forged, these turn up on eBay all the time and are cheap), chop up some lead chunks with a half-axe, and put the dipper with lead on the fire. When it's empty, repeat. No pot, electric or otherwise. My moulds are bag-type, some from Dixie Gun Works, some from the now defunct Rapine Moulds, and a new one from Larry Callahan. Wrap the handles in leather or get burnt fingers!
http://www.dixiegunworks.com/product_info.php?products_id=7965
http://www.bagmolds.com/

I will say that for starting out, a more modern mould with a pivoting sprue cutter is easier to use, and will produce better results. I just like doing things the old-fashioned way, I guess. I've never used much in the way of flux, just skimmed the lead when melted. Soft lead generally works best, if you can mark it with a fingernail, it's soft enough.

Rod

 

[TraprMike]

my balls are far more equal in weight then the store bought! To top it off ... it's fun to do!

:slap:

 

[stormcrow]

Thanks again fellas for the great advice. I'm going to start collecting/scavenging the tools this weekend. After that all I need is to look for some down time, the ingredient I have in least supply.

 

[Lonegun1894]

Rod,
I understand, and agree, but was trying to tell of my experiences and pass on my good habits when I do things right, and not my bad habits when I am being lazy (but comfortable). He will develop enough of his own bad habits as time goes on. But for what it's worth, I'm not above casting in my usual boots, jeans, t-shirt, and sunglasses. But having said that, I expect to get slightly burned on occasion--and it wouldn't be the first time.

 

[Sunkmanitu Tanka]

:haha: :rotf:

 

[capt_turk]

The best ladle or spoon I've found to pour the lead into the mold is a stainless gravy ladle. I've found if you leave the ladle in the melted lead, except for when you are pouring, you have longer to make the pour. I also rest my Lee molds on the edge of the pot an don't move it after I pour till the lead hardens. It seems to fill the mold better if it stays hot longer. I heat the mold in the flame before I start pouring and usually get good balls from the first pour.

I tumble the new balls in a ball mill for at least a half and hour. The sprue and any mold lines are gone then and they come out shiny black and slick as glass.