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Bullet Casting - introduction

As we muzzle-loaders are notoriously tight-fisted, we all eventually end up bullet casting. The economics are simple - one hundred 577 minie bullets costs around thirty pounds to buy, but the cost of pure virgin lead to cast them comes in at around four pounds. The economics are rather less simple if you're into revolvers or single shot target pistols, but even so at around eight pounds a hundred retail, casting provides a worthwhile saving. Of course on a cold winter's evening when you're all out of balls and the shoot's tomorrow it somehow seems a little less worthwhile.

Materials

All bullets for muzzle loading pistol shooting are cast from pure lead - the same being true for Minie bullets, so where and how do you get the lead. The simplest answer is to buy it from the MLAGB. They sell it from Wedgenock at around one pound a kilo. It used to come in ingot shaped sausages, each ingot being a kilo, but last time I bought any it came in much bigger chunks which required considerable ingenuity to cut up!

So what are the economics? Well the table below shows the best-case scenario including nothing for the costs of the heat source, flux, equipment, labour or anything else. Still, even with those taken into account it indicates a considerable saving. Plus if your piece requires a ball of non-commercial size then you're trapped anyway!

BulletWeight (grains) Bullets per kiloCost Each(pence)
.375 round ball81 1900.52
.451 round ball138 1110.9
.457 round ball143 1070.93
.577 minie (large cavity) 530293.44
.577 minie (small cavity) 560273.7