Cast bullet

[4] Jacketed bullets also function more reliably and are less likely to be deformed in the mechanical loading process of self-loading pistols and machine-guns.

Firearms were often sold with a mould designed for that particular weapon; so individuals living in remote areas would be able to manufacture their own ammunition rather than relying upon undependable supplies from local merchants.

The uniform fit of bullets from an individual mould offered superior accuracy when early manufacturing tolerances were comparatively large.

[7] Although some bullet casting procedures can be accomplished with heating elements used for cooking; care must be taken to avoid contaminating food preparation areas and/or utensils with lead alloys.

Young children are especially vulnerable to lead poisoning and are unlikely to appreciate the danger of shiny molten metal and newly cast bullets.

This means that the dross that is skimmed from the lead pot may pose a larger hazard than the metallic alloys.

The most successful cast bullet designs have a round or flattened nose rather than a long, unsupported ogive.

[9] One of the earlier efforts to obtain better high-velocity performance involves placing a very shallow cup of copper alloy over the base of the bullet.

These lubricants softened the black powder fouling for easier removal and reduced the tendency of bullets to leave deposits of lead in the barrel as they were fired.

Attempts to obtain satisfactory high-velocity performance with cast bullets have included experimentation with a variety of lubricant mixtures including such things as beeswax, carnauba wax, Japan wax, bayberry wax, paraffin, petroleum jelly, sperm oil, castor oil, stearyl alcohol, lauryl alcohol, graphite, molybdenum disulphide, mica, zinc oxide, Teflon, cup grease, lithium soap, water pump grease, and a variety of more modern lubricating materials.

[14] An alternative procedure is to re-heat cast bullets (usually in a wire mesh basket) in a temperature-controlled oven and then remove and quench.

One of the earlier attempts, which is still popular today with muzzle loaders and users of black powder rifles, prevents leading and obtains potentially better velocity and performance with cast projectiles involves application of a paper jacket.

Some prefer a relatively strong paper precisely cut to wrap exactly twice around the bullet with no overlap where the ends meet.

There is some question about whether the accuracy improvements result from the paper jackets or from the greater uniformity of shooting procedures by people with the patience to apply the patches.

A small number of dedicated target shooters still load paper-patched bullets at velocities up to about 2,000 feet per second (610 m/s).