You appear to have missed post #5.I must've missed something here. If the bullet was fully seated, and the man soaked the charge that tells me the ball had powder behind it. Why not just fire it out before he soaked it down?
My suggestion to weld was to be able to attach a drill bit to predrill the ball to prevent expansion when the ball puller is screwed into the ball. Mostly because it sounds like the o.p. will be making his own range rod.Well now that he's soaked the charge, the only way out is to pull it. I say clean the bore to get the soot out, then lightly oil the bore before you pull the ball so there's less resistance.
BTW, there's no need to weld anything to a range rod. Clamp the tips of each rod end into a vice, then center a drill press over the tip. Then drill a center hole on each end of the rod. Tap the thread size you need into each end, then thread on T handle on one side, and your choice of implement on the other. It's pretty darn hard to strip out a T handle or ball puller that's secured to a steel rod via good threads
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