We have received our pot from the shop. I am a bit embarassed/disgruntled that I didn't build it, but I don't have a shop to work in outside of my job and the other guys are getting a bit impatient.
We commisioned a 14" O.D.x 1/4" wall by 16" high pot. The bottom is 1/2". I drew up a bottom pour using a threaded t handle with a plug and matching, 1/2" seat. The seat sits on a block that is a 1/2 thick to get it off of the bottom. That feeds a 1/2" nipple to pour from. The pot probably weighs 40-50lbs. I'll post pics later when we start smelting, which should be this weekend. A cubic foot of lead is a tad over 700 lbs. This pot should be upwards of 500lbs, wet.
Why? Why not? There is a good reason. We are sitting on close to 4k in isotope lead and another 3-4000 in very clean range scrap. Even with this, we are going to be busy for a while.
The final two pieces of the puzzle are a burner and ingot molds. I have molds, but not for this volume. We have a 250k brewing burner and stand on order and should be here soon. It was a bit of a W.A.G. on size. I actually started considering a 500k untill I found out the other had been ordered. And, I will be reinforcing the enclosed stand or building a new structure around it. The ingot molds, I am fabricating from 8" channel at 2 1/2" long. They will be single molds and not ganged together. We are thinking around 20 will suffice and are entertaining the idea of putting them on a board that rolls on pipes under the spout for filling.
Would anyone like to speculate on the suitability of the burner for heating that large of a pot of lead?
Can anyone tell me anything about how much angle is needed on the end plates for the molds to get them to drop easily? Due to the volume being made, the plan is to tack at the bottom and lay the top out before welding into position. Machining or cutting on an angle wasn't an option. I'm hesitant to weld on the inside, but I know I will have to fill the gap if I don't. Gas welding the gap or filling it with brazing rod is looking like an option if I don't weld it. I'm figuring on ingots around 12lbs. Any other input on these molds is welcome.
Ultimately, the process will be as follows:
Iso lead and recovered indoor range scrap (bullseye range 98% of the time) will be smelted to ingots.
Ingots will be cast to 45 a.c.p. swc boolits in a Ballisticast Mark X that is awaiting a recut set of molds as we speak. It is a nice machine and I will post pics and video later.
Said boolits will be sized in in our vintage Star lubrisizer or yet to be received Ballisticast Mark 6.
After a quick trip through a 650 Dillon, the projectiles will be fired downrange at near slingshot velocity (it is bullseye pistol) through the ten ring and into the backstop. At that point, most material will be recovered and we will start all over again.
When we get rolling, I'll put some pics or video up. This should be a 3 or 4 guy operation and there should be more than enough work to keep everyone busy.