Hawes notes that the bullet making machinery described was obviously
far too complex and cumbersome to be carried into the field; the only
other means of making the bullets was by casting. The luxury of the
bullet making machinery described is also likely to elude readers, so
Hawes observations on casting will no doubt be of interest, and follow:
The appliances required, are the melting pot, ladles, moulds with
plugs for forming the hollow in the bullet, nippers, and the rectifying
machine. This is a small hand-worked machine, worked by means of a
lever with a handle at the end. To this lever is attached a spindle,
working horizontally in a socket; to the end of this is fixed a punch
of the same form as the hollow in the bullet; in front of this is
a die, funnel shaped, the smaller end being of precisely the same
diameter as the bullet; it is open at both ends, with its base towards
the punch, the punch is driven forwards into the hollow by means of
the lever handle, and the bullet pushed smartly through the die; the
superfluous lead being thus cut off, and the bullet at the same time
gauged or pared down to the required size. To preserve this die correct,
of course requires constant attention, gauging, and repair.
In casting bullets, the lead should be poured in rather slowly, after
having taken it out from the melting-pot carefully with a ladle.
Care must be taken to get a freedom from air-holes, and the moulds
should not be closed too tightly, but so that the air escapes easily;
for, unless it is allowed to do so, an uneven surface to the bullet
will invariably ensue. The moulds also should be of a proper temperature.
Practice alone can regulate the requisite speed in pouring the lead
in. When the lead has cooled slightly, the bullet must be taken out
with the pliers, holding it by the piece of superfluous lead, and
placed point first, as before described, in the die of the rectifying-machine.
The punch must then be forced forwards with a smart but firm pressure;
thus cutting off the superfluous lead and regulating the size of the
bullet.
The plugs of the bullet-moulds require occasional examining and gauging.
The following precautions, taken in America for casting bullets, are
recommended in the United States Ordnance Manual, and also in the
French "Aide-Mémoire d'Officiers d'Artillerie:
"Weigh the lead, fill the kettle (or melting-pot), and cover
it; as the lead melts add more, until within three inches of the edges
of the kettle. Cover with a layer of powdered charcoal one inch thick,
push the heat until paper in contact with the lead is inflamed by
it: this requires from one to two hours.
"Immerse the ladle and fill it about three-quarters full of
the lead, covered with the charcoal, which is kept back by a piece
of wood. The first castings are thrown back into the kettle, being
imperfect, from the moulds being cold.
"The diameter of some of the bullets should be verified from
time to time with gauges. The moulds must be carefully cleaned when
it is perceived that the lead sticks to them.
"With proper care, 100lb. of lead will give 96lb. to 98lb. of
bullets."
