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beleg2
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Reged: 15/08/07
Posts: 591
Loc: Bahía Blanca - Argentina
Casting problems
      #97597 - 25/02/08 10:27 AM

Hi,
I post this here becuse is about muzzleloading bullets.
I have been casting for one and a half hour and get almost 200 bullets.
My mold is a Lee R.E.A.L , 440 gn., muzzleloading bullet, so I cast them in pure lead.
I set the fire to get 700º (lower than recommended on other forum), use a ladle and a wet towel to cool the plate. I casted almost prefect bullets, until I check them with good light.
2/3 of the bullets from cavity closer to the handles were rejected and almost all the bullets from the other cavity also were rejects. All bullets have the same problem at different degree, the one you see on the picture (I do not know how it calls).



Is it a problem that solves casting at higher temperature? I set it at 700º because at higher setting the mold gets too hot.

Will these “bad” bullets affects accuracy? Just want your opinion.LOL

Thanks
Martin


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gatsby
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Re: Casting problems [Re: beleg2]
      #97598 - 25/02/08 10:42 AM

beleg2
Try casting at a higher temp. It can be a bit of a balancing act keeping the mold/lead at the proper temperatures for good casting. I have a sponge handy to cool my molds a bit if the get too hot. I also use a casting thermometer and try to keep the pot at the same temperature thru out the casting session once I determine a good casting temperature for the mold/alloy I am using. It is not as easy to cast with pure lead as it is with alloy. I do not use bullets which cast with major flaws but I know others that do. I actually weigh each bullet and discard any that greatly deviate from the "mean" bullet weight of that session.

--------------------
"Recoil is insignificant when there is a tiger on the head of your elephant" The Maharaja of Cooch Behar



Edited by gatsby (25/02/08 10:50 AM)


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szihn
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Re: Casting problems [Re: gatsby]
      #97600 - 25/02/08 11:35 AM

If you get "too hot" the bullets will have a frosty look to them
Contrary to popular belief, it DOESN'T HURT A THING" TO HAVE THEM THAT WAY.
If you need more heat, use it. I would no go much higher than 750 however.
I have found that adding a few very fine lines from the cavity to the outside of the mold to vent air is very helpful.
I use a graver, and vent my Lee molds with about 6 lines. I get excellent bullets that way.

One more thing
If you add 1 part tin to 30 parts lead, the metal will fill out the mold a lot better.


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beleg2
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Re: Casting problems [Re: szihn]
      #97601 - 25/02/08 11:44 AM

gatsby,
Thanks for your answer, I will try tomorow (when my wife is not at home) at higher temperature.

szihn,
Thanks you very much for taking your time to answer.
Do you use 1 to 30 for muzzleloaders?
I was affaid this would hardened the alloy to much for a REAL bullet.
Thanks
Martin


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Dphariss
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Re: Casting problems [Re: beleg2]
      #97625 - 25/02/08 04:18 PM

Quote:

Hi,
I post this here becuse is about muzzleloading bullets.
I have been casting for one and a half hour and get almost 200 bullets.
My mold is a Lee R.E.A.L , 440 gn., muzzleloading bullet, so I cast them in pure lead.
I set the fire to get 700º (lower than recommended on other forum), use a ladle and a wet towel to cool the plate. I casted almost prefect bullets, until I check them with good light.
2/3 of the bullets from cavity closer to the handles were rejected and almost all the bullets from the other cavity also were rejects. All bullets have the same problem at different degree, the one you see on the picture (I do not know how it calls).
Is it a problem that solves casting at higher temperature? I set it at 700º because at higher setting the mold gets too hot.

Will these “bad” bullets affects accuracy? Just want your opinion.LOL

Thanks
Martin




"cool the plate" may be your problem. Cool and bullet casting are not usually a good combination.
I would smoke the mould cavity with a wooden match and turn up the heat. Pure lead needs a lot more temp than a tin:lead alloy.
Yes they will effect accuracy.

Dan


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DarylSModerator
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Re: Casting problems [Re: Dphariss]
      #97643 - 26/02/08 01:11 AM

I've had blue balls when casting overly hot, but never frosted ones, with pure lead. Frosting comes from antimony in the mix and Steve's right, the frosting doesn't hurt the shooting capabilities of the bullets. All of my modern high velocity alloyed bullets are evenly frosted all over.
; I've been casting for a lot of years, well over 1,000 pounds of lead has gone through my moulds and I've never had to cool a sprue plate. When fast-casting with alloyed metal and iron blocks, I've had to singe them onto a wet towel at times to reduce the heat, but never just the sprue plate. I think that's a lot of the problem.
: 700F is not hot enough for pure lead. The pictured bullet shows that. When the lead inside the mould takes to long to harden, I set an aluminum set of blocks on a steel plate for a "few seconds"- as in count to 4 or 6. This is enough to suck the excess heat from them. Too long on the plate, and the mould cools to much.
: Martin - by the sounds of it, you are continually cooling your mould as you are casting and slowing your casting. You should be able to cast 30 bullets before the mould gets too hot - keeping a steady rythem. In 1 1/2 hours, with 200 cast, your rate is pretty good, but not enough heat. Wrinkled bullets shoot about as good as they look.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V


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szihn
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Re: Casting problems [Re: DarylS]
      #97648 - 26/02/08 02:00 AM



Hi Martin
To be honest, I don't use the 30-1 alloy myself because I use wheel weights. I get them free, so why pay for alloy?


However, I can't say that WW alloy is the same in Argentina as it is in the USA.


I used to run a company called Cast Performance Bullet Company in Riverton Wyoming. We made millions of bullets for various handgun and rifle calibers. I started the company (named
Hi-Performance Cast) in Gardnerville Nevada, and it was later moved to Yerington Nevada, and then to Riverton Wyoming. I give over my part of the company to a friend when it was still in Gardnerville, and he changed the name to Cast Performance, and then moved to Riverton Wyoming after I had moved to Shoshoni Wyoming.

Anyway, I only tell you this to let you know, I have learned a LOT about cast bullets and how to make them. I took the company over again in 1999 because of some difficulties that they were having, and the investors asked me to take it again, and get it back on track. In the time I was a partner, consultant and/or manager of that company we produced millions of bullets for sale all over the world. Federal Cartridge company used them in their Premium line of handgun ammo. The called them "Cast-Core" bullets, but we made them for federal.

When I left I turned over control to Kelly Broast who was my day shift foreman. He became general manager. After that He and his wife bought the company from the investors and it became theirs. About 2 years ago it was sold again to a man in Oregon.

Coming back to your question, tin will NOT make your bullets too hard for muzzleloaders. In fact, tin alone will not harden a bullet much at all. It does, but not enough to matter much. It need to be combined with antimony before it starts to make the bullets much harder. Tin in a 1-10 mix with lead will harden a bullet initially, but the alloy will work soften if it’s disturbed at all, so it’s deceptive to “harden” with tin alone. Tin’s main function in such allows is simply to cause the mold to fill out, so the bullets weigh the same.
Now if you combine tin with antimony you start to get much harder (and Daryl is right, the frosting
in a bullet comes from the presents of antimony and tin, not tin alone), but Led/Tin/Antimony also will work soften to a degree. The secret to very hard and TOUGH alloy that is not brittle, it to include a trace of arsenic, silver and copper. My alloy was mixed to include all 6. Our alow came at 22 brenell hardness, but unlike lino-type, it was not brittle, and would not break up if it hit heavy bone.

Now, that amount of hardness is not bad for muzzleloaders, but it’s hard to load, and so I don’t recommend it for most applications. For your REAL bullets I would mix 96$ lead, 2% antimony, and 2% Tin. Cast them at 750 degrees and let them air cool. Thake the time to over-pour the mold and let the bluuets cool slowly in the cavity. It's slower, but you get close to 100% good bullets, and no rejects. So your hourly production is higher over-all.

We did make some bullets for muzzleloaders that ran the same alloy and the same hardness, but they were made for “bullet rifles” and were sized and rifled to fit the individual rifles. The worked extremely well, but they were overly specialized, and there was not enough market for them.

Edited by szihn (26/02/08 02:14 AM)


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beleg2
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Re: Casting problems [Re: szihn]
      #97662 - 26/02/08 04:38 AM

Thanks for your answers and for shearing your experience.
Steve, wow that’s an impressive background!! I remember Cast Performance Bullets.

The fire is on, so I will be casting in some minutes.
I will try to cast at 750-775 º and I will not cool the mold every time.
I get the idea of cooling sprue plate from castboolits.com. It looks good and it let me cast without interruptions until I have no more lead in the pot.
The mold never get too hot. After the cavities are filled, I put the sprue plate over a wet towel for 1-2 seconds.

I will let you know how it works.
Thanks
Martin


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szihn
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Re: Casting problems [Re: beleg2]
      #97664 - 26/02/08 05:18 AM

Let the mold cool on it's own. Cooling the sprew will not allow the bullet to shrink as it cools and pull in hot metal from the top to fill the void.
To get excellent bullets, you should overfill. In other words, let a stream of metal pour over the top of the mold and back into the pot even after the cavity is full. Let it flow for about 4 seconds and then let the sprew cool on it's own.
As I said, it slows you down, but you still get more GOOD bullet every hour, because you don't have rejects.

Steve


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DarylSModerator
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Re: Casting problems [Re: szihn]
      #97680 - 26/02/08 10:29 AM

I don't pour lead over the mould but have heard of others doing it. I merely pour the cavity and leave a large pool on top which sometimes runs off the side, sometimes not. I still cast good bullets. If the sprue hardens too quickly, the mould itself is too cool and needs more time sitting on top, or casting to heat it up. I just dump that one into the sprue pot. Once the mould is the correct temperature, I can cast steadily until I've had enough, or have enough bullets or balls.
: Pure lead requires MORE heat than any of the alloys. I run WW alloy around 750. No wonder your REAL bullets are so wrinkled. Notice all the little lines etc, between the grease grooves - too cold - mould and alloy. At 725 to 750, it would be almost impossible to get the mould too hot.
; Martin - try 825 to 850 degrees. Keep that wet towel away from the sprue plate - youre just cooling that down too much. Are you using a lead thermometer or the reading of the dial on top of the electric mould? If using the dial, set it at high until the mould gets too hot - if it does, then turn it down to about 1/2 way between 7 and 8. I've touched the blocks onto a wet towel - never the plate. You want it hot, hotter than the blocks. If it gets too hot and the sprue takes more than about 4 or 5 seconds to solidify, just set the blocks down on a piece of steel for 3 to 5 seconds and you can resume casting. Get into a rythym with the casting and the mould will not get too hot and you'll turn out 150 or more PERFECT bullets per hour. As with anything, it takes practise. Pure lead needs a higher temperature than ANY alloyed lead. If the lead doens't turn a bit blue on top, it isn't hot enough. This is for pure lead only.
; Just goes to show that there is more than 1 way to get it done right. You can replace speed with heat or visa/vis - BUT - the lead must be hot enough to cast a perfect bullet and pure lead HAS to be hotter than the alloys.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V

Edited by Daryl_S (26/02/08 04:10 PM)


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beleg2
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Re: Casting problems [Re: DarylS]
      #97715 - 26/02/08 09:21 PM

Thank you very much!
I have been very busy yesterday but cast some very good bullets. I have to check them to sort the bad ones.
It tooks more than 4-6 seconds for the sprue to solidify and was very dificult to mantain enough lead over it. Lead flows too much and sometimes I get a hole in the spue.
I will try your advise of "set the blocks down on a piece of steel for 3 to 5 seconds".
Thanks
Martin


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DarylSModerator
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Re: Casting problems [Re: beleg2]
      #97722 - 27/02/08 01:52 AM

The mould must stay hot, Martin, and only cool it if it gets too hot. You can merely slow the casting and it will cool enough. The only good bullets are perfect bullets.
: An aluminum bar will work faster that a steel one for cooling.
: Any time there is a hole in the spure, that is a cull. There is a void inside the ball or bullet.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V


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beleg2
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Re: Casting problems [Re: DarylS]
      #97726 - 27/02/08 04:46 AM

Well,
just finished with the bullets.
From 135 bullets I rejected 33 and have some problems closing the mold (some lead between) and I have 24 oversice bullets that I will try someday.
After weighting each one I get the following:

C1 C2
458/459 6 7
458/460 7 10
460/461 13 18
461/462 10 4
462/463 1 1
463/464 1
38 40
Rejected 18 15
Oversice 11 13
67 68

C2 is the cavity closer to the handles and C1 the other cavity. For what I see there is no much difference between cavities.
Bullets are heavier than expected, according to Lee it is a 440 gn mold.
How much difference between heavier and lighter bullets do you recommend?
I would prefer to keep the bullets between 458 and 462 gn, 75 bullets.
Thank for the advises.
I will try again soon using an aluminum block to cool the mold if its necessary.
Thank
Martin

PS: can not edit the table right, hope you can underestand it, first mumber is weight range, then bullets from cavity one and then from cavity two.


Edited by beleg2 (27/02/08 04:50 AM)


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DarylSModerator
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Re: Casting problems [Re: beleg2]
      #97745 - 27/02/08 01:15 PM

Martin - about the oversized bullets. They won't be round. I guess you found you must be careful not to let lead spash inside the mould blocks. Lee moulds are worse than any others as to closure and alignment, but then, they're only 1/3rd the cost of iron blocks.
: I have some Lee blocks, but very much prefer iron blocks. Unfortunately, some bullets and balls aren't available in iron.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V


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beleg2
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Re: Casting problems [Re: DarylS]
      #97794 - 28/02/08 12:36 AM

Daryl,
Thanks again.
I will keep ovesice bullets just to try them. You are right, I get a little drop of lead inside the mould blocks.
I have to use this Lee mold because the REAL is the only bullet I can use in my double rifle. Do you know about other mold of 460 gn in .58". I can not use Minie bullets because the one in the second barrel would move on recoil. I have a Minie RCBS mold.
How much variation do you recomend in weight?
Thanks
Martin


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CptCurlAdministrator
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Re: Casting problems [Re: beleg2]
      #97803 - 28/02/08 05:00 AM

I also have a long history of bullet casting. It goes back to my youth when I couldn't afford to buy bullets.

I agree you want your alloy hot, and if using pure lead you need more heat. My casting has been both with wheelweights and with pure lead.

My experience is mostly with iron moulds, but I have used aluminum some.

I have a method I use when I cast, which you might find helpful. I always work two moulds. I fill one and carefully set it aside. Then I fill the second and set it aside. Then picking up the first mould I break it open, re-fill it, and set it aside. Then to the second mould, etc. etc., alternating back and forth. This method increases your production to almost double what can be done with one mould only, and it serves to maintain correct and even mould temperature all the while.

Try my method, and you will have good results.

Curl

--------------------
RoscoeStephenson.com

YOUR DOUBLE RIFLE IS YOUR BEST FRIEND.



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beleg2
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Re: Casting problems [Re: CptCurl]
      #97834 - 28/02/08 11:09 AM

Thanks,
I have use two mold some time ago but now I just want one tipe of bullets.
Martin


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DarylSModerator
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Re: Casting problems [Re: beleg2]
      #97842 - 28/02/08 12:45 PM

That's a good method, Curl- one I-too use is needing different bullets of the same alloy.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V


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Dphariss
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Re: Casting problems [Re: beleg2]
      #97898 - 29/02/08 02:49 AM

Quote:

Thanks for your answers and for shearing your experience.
Steve, wow that’s an impressive background!! I remember Cast Performance Bullets.

The fire is on, so I will be casting in some minutes.
I will try to cast at 750-775 º and I will not cool the mold every time.
I get the idea of cooling sprue plate from castboolits.com. It looks good and it let me cast without interruptions until I have no more lead in the pot.
The mold never get too hot. After the cavities are filled, I put the sprue plate over a wet towel for 1-2 seconds.

I will let you know how it works.
Thanks
Martin




Like most web sites there is some stupidity on "Cast Boolits". Cooling the sprue plate is right up there.
Generally speaking a bullet like a REAL bullet should be no harder than 1:20 tin lead. 1:40 to 1:16 will cast perfect bullets with a low reject rate even if weighed to +-.5 gr if the casting is done right. The tin lowers the temperature at which the metal will flow.
Generally pure lead and tin is the best alloy fro BP, either in MLs or BPCRs. Though I have had moulds that were poorly designed and needed near #2 alloy to shoot well.
The key is in the casting process, use hot metal, cast as a speed that keeps the mould hot enough but not too hot and segregate bullets by casting session. 2 different sessions with the same alloy and same mould will often be off enough to increase the number of culls when weighed.
Note that I am referring to match grade bullets but I use the the process for all cast bullets even RBs. Its not much more work and the bullets are more uniform. I relax the weight requirements when casting pistol or light weight rifle (hunting) bullets from a multi-cavity mould.
Bullets that are more than 1 grain light from the same cavity are useless for precision work.

Dan


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Dphariss
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Re: Casting problems [Re: szihn]
      #97899 - 29/02/08 02:54 AM

Quote:





I used to run a company called Cast Performance Bullet Company in Riverton Wyoming. We made millions of bullets for various handgun and rifle calibers. I started the company (named
Hi-Performance Cast) in Gardnerville Nevada, and it was later moved to Yerington Nevada, and then to Riverton Wyoming.




Hi Steve
Have you heard anything about WWs having the lead removed??
Found a post on another site that stated that WWs were going lead free and if the new were mixed with bullet metal it was uncastable.
Just curious.


Dan


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szihn
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Re: Casting problems [Re: Dphariss]
      #97900 - 29/02/08 04:16 AM

Yes, I have heard of zinc and steel weights that are beings caled for by the anti-gun elements of our government
They hide the true agenda under the bogus "environmental" excuse, but the idea is to get lead out of the hands of shooters
We don't yet know when it will happen, but rest assured, if it doesn't happen the next step is to make private ownership of lead a crime. It's "bad for the environment”. Never mind that lead is elemental, and we got it out of the ground in he 1st place. It’s a naturally occurring element, and it’s “part of nature” so it’s OK if it’s in the ground.
If we take it out of the ground and then put it back in the ground when we shoot, at the point it come out of a gun , or could come out of a gun -----THEN IT'S POISONOUS"!!!!
If that premise seems illogical to you, it's only because it is.


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beleg2
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Re: Casting problems [Re: szihn]
      #97930 - 29/02/08 08:27 AM

Thanks Steve et al,

I also separate bullets from different sessions and I usually try to use bullets with no more than 1 gn of difference in weight.
In this case, a difference of 1 gn means 0.21%; 2 gn 0 .42%; 3 gn 0 .65% and 4gn only 0.87%.
IIRC most of bullet makers have more than 0.5% of variation in weight.
I will have to work on my casting and I will try some tin on my pot.
Thanks for all the advises.
Martin


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szihn
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Re: Casting problems [Re: beleg2]
      #97933 - 29/02/08 08:51 AM

Good luck and good shooting.


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Dphariss
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Re: Casting problems [Re: szihn]
      #97941 - 29/02/08 11:13 AM

Quote:

Yes, I have heard of zinc and steel weights that are beings caled for by the anti-gun elements of our government
They hide the true agenda under the bogus "environmental" excuse, but the idea is to get lead out of the hands of shooters
We don't yet know when it will happen, but rest assured, if it doesn't happen the next step is to make private ownership of lead a crime. It's "bad for the environment”. Never mind that lead is elemental, and we got it out of the ground in he 1st place. It’s a naturally occurring element, and it’s “part of nature” so it’s OK if it’s in the ground.
If we take it out of the ground and then put it back in the ground when we shoot, at the point it come out of a gun , or could come out of a gun -----THEN IT'S POISONOUS"!!!!
If that premise seems illogical to you, it's only because it is.




They can't seem to grasp that a lead bullet is not like lead acetate or some other oxides and such. Lead Acetate (sugar of lead) is how the Romans poisoned themselves, they used it to sweeten their wine. If it were as bad as we are lead to believe they would have wiped out the Roman aristocracy in a week.
They have a lead smelter at East Helena and they had air monitors around the town to check to see how bad it was. I guess it was not too bad right across the highway the monitors are all gone so far as I can see. People still live there.
Its all just crap to give people something to worry about. If they want to worry they should forget lead and global warming and look into Dioxin which really IS bad and is increasing in the environment all the time.

Easy to get into a rant here...

Dan


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DarylSModerator
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Re: Casting problems [Re: szihn]
      #97950 - 29/02/08 01:27 PM

Apparently, in the States, youmust be careful about dumping WW's into the lead pot as there are stick-on weights that are almost pure lead, as well as some zinc ww's that will destroy the whole melt and contaminate the pot as well - so I've read on the cast bullet forum.
; Lucky for us, we can easily weed out the stickons and stick with the harder weigths that seem prevelent here in Canada.
; Steve- you're right about the lead and the silliness of claiming it is contaminating the countryside. That's bloody well where it came from to start with.
; Seems the lead shot ban is expanding as we knew it would.

--------------------
Daryl


"a gun without hammers is like a Spaniel without ears" King George V


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