Alloys will vary depending on the application. More information can be found in the excerpt from the HANDBOOK OF COMMERCIAL BULLET CASTING located in the book section. Magma test casts their molds using an alloy of 6% Antimony, 2% Tin and 92% Lead.

The mold isn’t hot enough or there is oil residue in the mold cavity. Just drop the wrinkled bullets back in the pot and recast.

Many manufacturers coat their molds in a deep layer of oil or some petroleum based preservative to prevent rust. Rust is a consideration if you don’t know how long the mold will sit on a shelf before it is sold. Some of the old cast-bullet manuals say the best way to remove this oil is by casting until the oil is burned off. DON’T BELIEVE IT. If you begin casting with oily molds, the oil will eventually burn off but it leaves a carbon based residue that will imprint on all of your bullets. The deposit is not only difficult to remove, it will take a long time before the mold will yield acceptable bullets. The best way to remove the oil is boil the mold in water that has some detergent in it. Immediately after the oil has been removed, rinse the molds in clear boiling water to remove all traces of the detergent. Dry the molds completely. If you leave any water, the mold will begin to rust in that spot. Be absolutely certain that all water has been removed before you begin to cast. If any water remains in the cavity, a small explosion will splatter molten lead everywhere. Magma molds are test cast before shipping and do NOT have an oil coating.

Short term: Spray with Master Lube to prevent rust and store in covered container. Long term: Spray with Master Lube and place them in an air tight container with a moisture-absorbing desiccant.

Antimony is a metallic chemical element (Sb). It is used to harden other metals. When two or more metals are mixed together they are referred to as an alloy. The typical bullet alloy is made of lead, with antimony added for hardness and tin added for ease in casting.

The best casting temperature for any given alloy is the coolest temperature that gives you the best bullets. Every alloy has its own "best" temperature based on the percentages of component metals. Temperature is also affected by air temperature and humidity, and the accuracy of your temperature controls. Temperature is further influenced by the heat absorption/retention of the mold itself. Rule of thumb: Use the coolest temperature that makes good bullets, in that mold, from that particular alloy, on that day. This trial and error method applies to either hand casting or machine casting.

When it comes time to move into automated machinery, consider the Mark 6 Bullet Master and the Lube Master. The Mark 6 will cast up to 4,000 bullets in an hour. The Lube Master will size and lube up to 8,000 bullets an hour. If you plan to cast about 10 hours a week, the Master Caster will produce about 5,000 bullets for you. Using the Magma Star-sizer, you can size and lube 5,000 bullets in about 5 hours. Both of these are manually operated machines.

There is a casters legend that claims the base of the bullet must be smooth and properly formed. Field work has disproved this theory. Instead, tests have proven the single most important factor in determining a bullet's accuracy is the relationship of bullet diameter to the bore. The bullet should be .0005" to .001" larger than the bore. Other than that you must also consider the following:

• Selecting the correct alloy for the type of bullet to be cast.
• Loading the cases to the proper maximum overall length of the finished cartridge and the cartridge fits the firearm properly.
• Being aware of the work-soften factor as you size bullets. Alloyed lead becomes softer as it is swaged. Size as soon as possible after casting.
• Making certain the alloy remains clean.
• Use the correct antimony and tin ratio for the expected velocity of the bullet. As a rule of thumb: 3% antimony for low velocity; 6% antimony and 2% tin for medium to high velocity; 12% antimony and 4% tin for highest velocity bullets. Pure lead should be used for muzzle loader balls. If 3% antimony doesn't cast well in your particular set of molds, try adding 2% tin to it in the form of plumber's fifty-fifty solder bar. The added tin does not increase hardness significantly but does improve the castability of the alloy.
• Lead base bullets harden or soften with age. Lead-tin-antimony alloys slowly harden over the course of about three weeks, and then their final hardness stabilizes. The age hardening quality can affect the ultimate quality and accuracy of the bullet. Tin-lead alloys either do not harden at all or age-soften depending on what specific alloy was used.
• An ineffective lubricant can also cause accuracy problems. Not all lubricants work with all bullets, in all firearms under all conditions. For a general dependable lubricant, try Magma lube.

Fins are caused by mold blocks that are not closing properly. If you suspect a mold block problem, remove the mold and inspect it for foreign matter and machine burs. Clean the mold carefully but thoroughly. Pay attention to the small grooves cut into the mold face leading to the bullet cavities. These are vent groves and their purpose is to allow air to escape from the mold cavity when the molten lead is poured in. These grooves are typically .0015" to .002" deep. If these grooves become plugged with any foreign matter, the bullets cast in the mold's cavity will not fill out properly.

Complete information on calculations is available in The Handbook of Commercial Bullet Casting. In the chapter discussing alloying and refining, a compositional breakdown of various metal types is listed as well as the simple equation you will need for calculating the ratio of material to another. If you don't want to bother with the math, use the Alloy Program. This is the computer program that automatically computes the cost and materials used in the book. The program is available on 5.25 or 3.5 disk for IBM compatibles. It can be run with Windows like any other DOS based program.

If you live in or near a major city, you can contact a commercial analytical laboratory and have them analyze the bullet alloy. If a laboratory is not available locally, you can get contact information from the yellow pages of your nearest major city. The library should carry the yellow pages. If you have access to the Internet, this is also a good source for finding a lab and using the yellow pages right from home. Check with the Laboratory for information regarding their procedures and pricing. They may charge for each element they test for or have a simple fee for a complete analysis. If the laboratory tests for each element, request an assay for antimony, calcium, arsenic, copper, aluminum and zinc. The lab will always report the balance as lead. The above elements account for the vast majority of casting problems, particularly aluminum and zinc. Many lead foundries can also perform this testing. If you purchased the lead from them, they may not charge or they may already have the analysis available. Foundries can also be found in the yellow pages as directed above. Once the problem element(s) has been identified, re-melt and adjust the alloy by adding the appropriate materials to compensate for the problem and bring your alloy back into the proper ratio. Another solution is to dilute the inferior material with quality material until the results meet your requirements.

Cowboy shooting usually requires cast lead bullets. We have over 100 styles and calibers to select from. Many manufacturer's molds can also be adapted to run on our machines.

"Best" is a very subjective term based on individual preference. However, accuracy should be a prime consideration in any choice. The most common is a 45 caliber which is available in a variety of styles. For safety, always choose a flat point bullet when you are using a tubular magazine. In a tubular magazine, bullets are loaded end against end. A round nose bullet would place the pressure of the nose against the primer of the preceding bullet, which could cause a dangerous chain firing within the magazine itself.

All cast lead bullets are premier target shooting bullets. Cast lead bullets are not for assault weapons. We have more than 100 molds for cast lead bullets. Many manufacturer's molds can also be adapted to run on our machines.

For steel targets, select from round nose or conical nose. For long range shooting using steel targets, flat points are best. Many manufacturer's molds can also be adapted to run on our machines.

That depends on the result you are looking for. A wad cutter will punch a perfectly round hole in a paper target. This is important in many scoring situations. However, because the nose is completely flat it can take a little longer to load. A semi-wad cutter, which still has a flat nose but it has been tapered in from the base diameter, is faster to load. Because of the tapering, the hole produced in the target is more frayed, not as perfectly round. It has a similar effect to jabbing a pencil through a piece of paper. Both are equal in accuracy. Make this personal decision based on the need for high score vs. speed in loading.

Combat shooting is usually speed shooting with semi-automatic gums. All 38's, 38 supers, 9mm, 40's and 45 automatics can be used. Good bullet choices are either round nose or flat points. Popular wheel guns (revolver type) are usually 38 and 45 calibers.

The Unlimited Class covers a huge category. Use light weight bullets such as a 9mm - 115 grain; 38 -125 grain; 38s - 115 grain; 40 - 140 grain; 10mm - 140 grain; 44- 180 grain or a 45 - 150 grain.

A grain is a unit of measure used in determining the weight of a bullet. One pound equals 7,000 grains, exactly. A heavier bullet is more accurate for long range (over 100 yards) because it retains its velocity. A lighter bullet can use more powder than a heavier bullet in the same size case. The lighter bullet will be faster. Example: a 9mm-115 can travel faster than a 9mm-147.

Explaining bullets would require a small book in itself. For brevity we will confine this to cast lead bullets. A bullet is the metal projectile that, along with primer/gunpowder (explosive), goes inside a metal, usually brass, case. The assembled bullet and case together is called a cartridge. The size of the bullet or cartridge needed is determined by the interior diameter of the gun barrel. This measurement is called a bore. A .38 caliber gun uses a .38 caliber cartridge as a standard rule. There are exceptions.

The type of bullet selected for loading into a case is dependent on the intended use or personal preference. If you were going to be paper target shooting, you would want a wad cutter or semi-wad cutter because they leave distinct, easily scored, holes in the target. For use with a metal target, a flat point, round nose, or combination is a good choice. In a tubular magazine where the nose of one bullet touches the end of the preceding bullet, NEVER use a round nosed bullet. A round nosed bullet can be extremely dangerous if the pressure from the succeeding cartridge on the previous cartridge's primer causes a premature explosion inside the magazine.

The bullet's base is beveled (tapered inward) to ease insertion into the case during reloading. Our designation for this is BB.

All bullets need to be sized and lubricated after they are cast and before they are inserted into their case. A grease groove, also known as a lube or lubricating groove, allows a place for the lubricant. If you are using a manual machine like the Magma Star-sizer or an automatic sizing machine like the Lube Master, the lube will be placed precisely in the groove at the same time that the bullet is sized.

A single lube groove provides one place for the lube. A double lube groove provides two places for the lubrication and so forth through the other lube groove numbers.

Competition opportunities have increased in recent years. There are four main categories for competition. IPSC is usually for semi-automatic weapons though some revolver type weapons are used. Silhouette, bullseye/target and cowboy action are other types of competition that are also popular. Their equipment focus is on revolver or lever action weapons. Competition shooting uses all types of firearms.

Your local gun club or target range can give you more information on what is available in your area.