Mogollon Rendezvous 2009 Outpost Report

Outpost Area: Tonto Buckskinners

Activity: Bullet casting

Author: Dan Wenger

Summary / goals of activity:

  • To teach boys how to moldround lead balls for muzzleloading rifles from molten lead using metal molds.
  • To teach the boys about the hazards and safety aspects of working with molten lead.

Safety Concerns:

  1. It is critical that no water, spit, perspiration, rain, dew, soda, etc ever get in the molten lead pot. If so there will be a huge explosion as the molten lead is sprayed out in all directions and any body part that is hit will be burned badly.
  2. Scrap lead and especially wheel weights need to be cleaned up, melted down and pour into ingots prior to the event to reduce the risk of a lead pot explosion, eliminate excessive contamination/dross, produce a better quality round ball, and make it safer to add the lead to the pot.
  3. Avoid spilling molten lead on shoes or other parts of the body.
  4. A first-aid kit capable of treating severe burns, and a container of cold water are essential.

Staffing needs. (Assignments, and tasks to man)

  1. This activity has been done with two people, but more would be very useful.

Layout and location of area. (Sq feet, tables, canopies and chairs, etc use photos)

  1. This is an activity that requires a sturdy table and a ramada or canopy to protect the molten lead from the possibility of rain. About 200 square feet are needed for displays, equipment, and room to work.
  2. See photos below.

Special skills, training or certifications needed.

  1. Staff needs to be trained to melt lead in a lead pot over a propane burner, to maintain an ideal temperature of the lead pot,to skim off the dross or slag,to pour the lead from the dipper into the mold, and then cut the sprue to open the mold to release the bullet, and the skill to teach the boys to safely do the same.

Materials list (qty, source, cost, prep, leadtimes, etc)

Item / Source / Cost
($) / Quantity / Comments
Pure lead (preferred)
or cleaned wheel weights that have no adhesive or metal clips. / Scrap yard
Tire stores / 30-50 / 100 lbs / Scrap yard (American Metals)
Obtain used wheel weights from tire store. WW should be cleaned & pre-melted into ingots.
Large propane tanks or Coleman fuel for stove / self / 25 / 2 / About 8 lbssize tank
A propane burner that will hold the lead melting securely / Self or borrow / NA / 1 / Coleman white gas stove works well too.
Melting pot (cast iron with handle and pour spout) / Midway, Cabelas, Dixie,
Midsouth / 20 / 1 / Capable of holding 10 lbs of lead. Can use clean, small Dutch oven with lid.
Lead dipper / Midway, Cabelas, Dixie,
Midsouth / 23 / 1-2 / Lyman current product is best. Old RCBS are also good.
Avoid Lee dipper.
.490 cal double cavity round ball mold with handles for each / Midway, Cabelas, Dixie,
Midsouth / 35 ea
55 ea
33 ea / 2-3 / Lee are aluminumcome w/ handles (more fragile)
Lyman & RCBS are steel
Handles for Lyman/RCBS
Bees wax / Home depot / 5 / 1 / Get toilet wax ring. Add small amount to lead to bring out dross.
Large old spoon to skim off the dross from the top of the molten lead. / Self
or DI / 1 / 1 / Needs to be about the size of soup spoon or small ladle to enable getting in pot.
Lead Thermometer (up to 1000’F) / Midway, Cabelas, Dixie,
Midsouth / 50 / 1 / Spend the extra money and get the RCBS unit. It is the best.
Sprue cutter / Self / 3 / 2-3 / Cut 1” hardwood dowel or hammer handle to ~12”
Frankford Arsenal Drop Out Bullet Mold Release Agent and Lube 6 oz Aerosol / Midway / 13 / 1 / Spray mold cavity sparingly to facilitate ball removal from mold
Chairs / ADC / NA / 1-4 / Enough for staff
Table (small or large) / ADC / NA / 1
Water Cooler (3-5 Gal) / ADC / NA / 1 / Need about 15 gal of water
Garbage can and liners / ADC / NA / 1 / Need 3 liners
First Aid Kit / ADC / NA / 1 / Standard items
Cooler with blocks of ice / ADC
Refreshments for staff
Hand cleaner and paper towels / ADC / NA / 1
FRS radio and batteries / ADC / NA / 1 / Use to contact main camp for assistance or emergency

Workflow Narrative of how to make it work and biggest challenges.

Scoring strategy (team dress, cheer/spirit, teamwork, time (if timed), quality of work, etc)

  1. There is no score; this is not a timed event.

Outpost awards: (Typical awards, details, and costs.)

  1. There is no prize other than the ball the boys keep and put in their medicine bag as a memento of the Rendezvous.

Transportation of materials, set-up, tear down resources or special tools.

Alternative Contacts or Content Experts:

Contact / Phone Number / Email address / Comments

Photos of actual operation: