TN.Frank said:
I'm going to try and come up with somekind of paper shot cup as well, I don't like lead in my barrel.
There are a variety of possibilities, including one really easy one that almost looks traditional. I use it a lot because my 16ga has rough bores and scrubs the shot really badly if I don't use some sort of protection.
Picture a 2-petal shotcup without a cushion or a gas seal, similar to the old ALCAN shot protector, for example. Think of it being made out of heavy paper (drywall spark-tape works in my 16ga and is a perfect width) or light card stock (business cards, file cards, bristol board). Open that out flat and draw a rectangle around it - that's all you need. I'm going to be lazy and copy-&-paste some notes I wrote up on it.
Hope this helps,
Joel
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2-petal "clamshell" shotcup:
- This is similar to the Alcan "shot protector"
- It can be made from either thick paper or light cardstock.
- The basic shape is a rectangle, with a width of 1/2 the bore circumference, or just under, and a length of the bore diameter plus twice the height of the shot charge; possibly with cuts or cutouts around the "base" in the centre of the rectangle to facilitate folding. They are reasonably easily laid out using hand-drawing, spreadsheet cells (without full base details), or a CAD program. With manual or CAD drawing, one can add details of the shotcup's base, and secondary lines for a narrower petal width for use inside cartridges or for inner petals of "fat-cross" shotcups (see below). This gives a compact layout with little wasted material.
- If the material is not too stiff, the shotcup can be made from the initial rectangle with no further cutting: wrap it around the end of the "former" (see below), align and form into a cylinder, then fold in the "corners" on the base under.
- If stiffer, one can either cut away excess around the base, or make cuts into the base and fold the excess up into short reinforcements, either inside or over the outside of the base of the petals.
- A typical spreadsheet-cell layout I use looks like:
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| : \ | / : |
| : 16ga | : |
| : ---- + ---- : |
| : | 1.25oz Pb : |
| : / | \ : |
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In the actual spreadsheet, the boundaries are provides by the cell borders. The markings are done using a fixed-space font like Courier. The "cross" in the center helps one align it on the "former", the diagonal lines near the middle show (approximately) where to make the cuts to facilitate folding and wrapping cardstock, and the dotted lines near the ends show (approximately) where to trim it for a 1-oz shot charge instead of the 1.25oz.
- They are easy to form at loading, especially if pre-formed then opened out again for storage.
- Cardstock MAY help tighten the pattern a bit more than the paper, by holding the shot together somewhat until it all clears the muzzle and no is longer being accelerated.
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A "former" is a dowel or other cylinder around which one shapes, rolls, creases, etc. the shot protector to ready them for loading. It might be the "wad starter" (see below) or it might be a separate device. As noted below, it should be somewhat smaller than bore diameter, so that the finished shot protector just comfortably enters a fouled bore. The term is used by extension from the device of the same name used for rolling musket cartridges.
A "wad starter" is a device similar to a short-starter for balls or bullets, used for forming and/or inserting these shot protectors on loading, except possibly for a pre-formed shotcup or for a cartridge.
- The shaft should be long enough to insert the longest shotcup used so that it is slightly below the muzzle, yet short enough to allow one's fingers to fit comfortably around the handle and down the shaft far enough to hold the petals in place when forming and inserting the shot protector, while holding the wad starter with the handle in one's palm.
- The shaft should be somewhat smaller than bore diameter, so that the shot protector fits reasonably closely around it and just comfortably enters a fouled bore, while still allowing the starter to be withdrawn without pulling the shot protector back out. For example, I use a 5/8" dowel (.625", approx. 20ga) for a 16ga (.665") bore (stuck into a plastic champagne "cork" for a handle).
- In some cases, it is possible to use one's finger for this function, especially if the shot protectors have been preformed, or preformed, creased, then opened flat again (see below).
It is often easier to pre-form the shot protector, getting the petals even, creasing the edges of the base, etc., reopen it flat for compact storage and transportation, then reform it quickly on loading.
If one uses over-powder wads that require some force to ram down, it is probably preferable to ram these down first, then assemble the cushion wad (or the last o/p card, if no cushion is used), the shot protector, the shot (and buffer, if used), and the over-shot wad, and ram these down together, following the usual procedures to prevent an "air spring" pushing them back up.