Research Update
So this is again running with the notion that I can match the ballistic profile and kinetic energy of a lead bullet but with using non-lead metals. The idea is to make lead and non bullets synonymous in terms of raw kinetic energy, ballistic profile.
The test rifle round will be 90-100 grain 243. This should cut costs with making the bullet. The idea is that this will be a hunting round or something I would cast for lead free hunting. This isn't practice or plinking round, it just simply is supposed to mimic cheaper lead bullets.
#1) Tungsten/Bismuth composite bullets (most seriously thought out idea I've had yet)
How they will be made.
https://www.rotometals.com/lead-free...ismuth-12-tin/
88%/12% bismuth/tin will be act as the volume of the bullet. While tungsten is merely the weight.
They will be made just like casting a regular lead bullet. Then hollowed out via drill and a chunk of tungsten rod will be inserted and sealed in. The tungsten chunk should bump it up to lead density easy. the rod does not have to be very long.
All in all, we are talking about 75 cent bullet, that's the bullet not the actual round with case and all. A significant amount less than I thought it would be, funny what a little research can do.
This will likely be the very first thing I try.
So far I have 2 ideas, yes the drawings aren't to scale they are rough, but the tungsten chunk will be tiny. 8mm long 1/8" diameter chunk weighing roughly 19 grains. I have 2 design ideas in mind.
Legality concerns
Ok so I did a fair bit of research. The one think that struck me was the use of the word "Core" (which has a differing definition, legally this bullet would be a Bismuth/Tungsten core that is clearly not designed for armor penetration but instead for improving kinetic delivery from a smaller bullet). Smaller bullets are generally better to shoot (it's just the fact that lightness means it can more easily effected by wind), a way to fix this is to make the bullet denser. Denser bullets have less surface area and are less effected by the wind.
-- >>> To compare M855 would be illegal if it weren't for a very specific wording.
This states that the bullet must be entirely made of the controlled materials, that is tungsten, brass, and what not. What I'm proposing would be 80% by weight (more so by volume) bismuth (legal), and 20% tungsten (illegal). Much like the M855 is made of steel (illegal), and lead (legal).a projectile or projectile core which may be used in a handgun and which is constructed entirely (excluding the presence of traces of other substances) from one or a combination of tungsten alloys, steel, iron, brass, bronze, beryllium copper, or depleted uranium; or
for clarity I'm calling this an unjacketed Bismuth alloy/tungsten composite bullet.
- it is my belief that it is here I would have strong precedent in fighting the ATF if they decided to arrest or whatever over this (I would win, as they would have to prove intent to disobey the law). Or, I would at least get told to stop, which I would happily comply (as I don't have the resources to lobby for this).
however I strongly suspect that this will be swept under the water as I don't intend to sell these bullets these are for my personal use. I likely will have more lead bullets than I have these on hand (as these are more of a specialty round). This wouldn't really catch attention.
#2) Silver/platinum alloy rounds
This will be done more than likely, for the lols. But it more than likely will not be a hunting round I use if the Tungsten core bismuth rounds work. But essentially the will be made from silver 90/10 from fine materials. The rounds will also likely be milled.
30-40$ a round (308, 150 grain standard).
Thoughts?