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The second and not so expensive of difficult option is knurling. Patching those tiny bullets must be difficult. The smallest bullets I have patched were .30 cal. 100 gr. and I found...

Ross Setfried wrote an article on paper patching jacketed bullets for "odd" calibers where bullets are not readily available. He used the "knurling" process Beemer mentioned.

I you want a copy of...

If you want a cheap hardness tester try the pencil test method:

https://castboolits.gunloads.com/showthread.php?75455-Testing-hardness-with-pencils/page13

I bought a Staedtler drawing pencil...

Yikes! Those are a bit on the pricey side! If I had that much money for a gun I'd buy a Paradox gun! I don't think I could justify $4000 for an air gun. In fact I couldn't justify $4000 for most...

This an area I have no personal experience with except for a bit of reading about the hard nose target bullets. I have two old books "Black Powder Guide" By Nonte and the 2nd ed. of the "Black Powder...

I was thinking more of shear in the flat glue line when the soft lead body slugs up to fill the grooves. Any distortion in the lead would put large shear forces on the glue line and I am sure it...

I'd agree that casting two separate pieces and swaging together is likely going to give a better result but is also far more complicated and expensive than casting with two dippers.

As noted, I...

No!

Lyman used to make two part bullet moulds where you cast a body with driving bands and gaping HP like cavity then you cast the nose separately. Once bth were cast the nose had a conical base...

Some of what you want to do is quite easy and several posters here have milled moulds to make boolits lighter, removed gas check shanks and lapped to make cavities cast larger.

For cas check shank...

What I copied is below. I have limited this post to just the wads/wad stack since this is a Tri-Ball load thread

#1

WAD: X12X gas seal from BPI / "2" or "3" 12 ga. Nitro Cards sitting directly...

My opinion, for what it is worth, is to cast a bore slug and lap the bore end to end using valve lapping compound. That should remove the roughness so at least then you can see what you have to work...

Out of curiosity I just laid this out in AutoCAD and with layers of two 000 balls, assuming 0.360" balls and 0.738" choke you stated, there should be 0.009" radial clearance between balls and bore.
...

Maybe a silly suggestion but would a paper tube work? Heavy craft paper or very thin card like business card stock could easily be wrapped around a dowel to curve it and cut to length then insert...

I have to think that .303guy is right in that due to the mass of the bullet (heat sink) and short duration of burn the Teflon tape doesn't get hot enought to melt or burn in any significant amount...

I think about the only relevant advice I can offer is that for my smoothbore guns I find that a snug fit of slug in wad to bore giving a fairly stiff push through the barrel force tends to provide...

I will be following this thread! I bought a Lee 000 mould and cast buckshot but haven't got around to loading any yet. I will gladly pilfer whatever information I can get on this thread!

Longbow

There were other choke tube systems similar to the Cutts like the Pachmayr Power Pac:

https://i.postimg.cc/fb0tpDNw/s-l400.jpg

and Poly Chokes that used a silver solder on barrel adapter and...

Are you shooting rifled gun or smoothbore?

For rifled gun soft lead may provide better accuracy due to set back/obturation helping with fit to bore. Lee recommends using soft lead for casting...

Cooling fins are a good thought. Also possibly using aluminum round bar would make a lighter mould and easier to machine as well as being a better conductor for heat. Most of my push out moulds are...

You are probably right. It looks as though the wad has a divot in it to cradle the ball but the balls are flush with the tail of the slug after firing. Does the divot flatten out at firing?

I...

Cap'n Morgan... thanks for posting that! It shows how much abuse those wads take and why a cushion leg reduces pressure due to give. A 10,000 PSI kick in the butt takes its toll!

What is your...

Charlie Horse... did you save the slug? I hope so! I always like to recover boolits and slugs so I can examine and learn from them. If accuracy is good there may not but much to learn but if accuracy...

Well then, I guess we need to come up with a home brewed and cast Tru-Ball clone!

I have a buynch of slugs loaded and have to get to the range to test them. These are a continuation of my...

Yikes! That is quite the collection! That makes my piddly haul look insignificant. I am jealous!

Are those all yours or is that a collection from multiple shooters from a range berm?

I see a...

Barry... I have seen this same thing many times when recovering slugs. Also, the Lyman 525 gr. sabot slugs really shorten up and the skirt goes from tapers to cylindrical in the last 3rd or so. These...