Overlooking the New River, Shot Tower was built more than 150 years ago to make ammunition for the firearms of the early settlers. Lead from the nearby Austinville Mines was melted in a kettle atop the 75-foot tower and poured through a sieve, falling through the tower and an additional 75-foot shaft beneath the tower into a kettle of water. For a small fee, guests may ascend the tower which is on the National Register of Historic Places.
http://www.dcr.state.va.us/parks/shottowr.htm
In 1782 an English plumber named William Watts saw possibility in that. He realized that if he dropped molten lead far enough through the air, it, too, would form into spheres. The surface tension of lead is a lot higher than that of water, so it forms very perfect spheres indeed. He saw that he had a new way to make buckshot.
Watts went back to his brick row house in Bristol and began adding floors to it. It was already three stories high. He doubled that. He put some castle-like trim on the top and called the design Gothic. He wanted his neighbors to like the addition, but the real action was inside his strange new home.
He knocked holes through each of the floors inside and put a water tank at the bottom. At the top, he poured lead into a sieve. The lead formed into spheres as it fell six floors. By the time the drops hit the water below, they'd started to solidify. The water caught and cooled them the rest of the way.
Up to then, most shot was cast. That was very labor-intensive. Shot was also made by pouring lead into a sieve over a barrel. That really did give tear-shaped drops. Before Watts, no one had yet realized that a much longer fall would give spheres.
Watts saw how he might greatly cut the cost of making high-quality shot. Then he gambled his home that it would work. And it did. Shot towers like his sprouted all over England and Europe. In 1808 Jefferson imposed the Embargo Act. That ended our shot supply. So we, too, began making shot towers.
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http://www.uh.edu/engines/epi422.htm[/url]
Everything I have ever read and seen said the shot towers purpose was to drop the lead from on high. I know you can make shot a few inches from water, and I have photo's of rupert shot makers and "screens" made by folks, who would drop the shot onto a blanket anchored in a stream or into barrels of water. One description states the natives would stand on a high bank overlooking the stream to drop their shot, as it gave a better product (Museum of the Fur Trade Quarterly).
Most modern shot makers use a plate which the shot rolls across to round it, eliminating the need for the tower.
I have tried making shot a few times with limited success. I do like the look of the shot with the "tails". I hear it actually shoots well and stabilizes quickly with the small tail. I will get it some day...I hope. Intresting subject, Matt