Introduction
Small-Arms Ammunition
The Bullet
Bullet Casting
Base Plug
The Cartridge
Cartridge Manufacture
Packing
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Role Your Own!
Mindful that soldiers may find themselves in the position of having
to manufacture their own cartridges, recruits were instructed on their
method of manufacture. The following extract from a Musketry Instructors
manual of 1853 explains the process. Note that the accompanying illustrations
have been extracted from Hans Busk's "Handbook for Hythe,"
(London, 1860 and reprinted by Richmond Publishing Co. Ltd., Surrey,
England 1971- SBN 85546 156 X), as those from the manual will not reproduce
well. The two sources are however essentially the same in detail.
Manufacture of Cartridges
Having cut the paper according to the size and patterns shown,
for cartridges for the rifle-musket or carbine,-
- Form the powder case. Roll the "stiff paper" pattern,
tightly about 2½ times round the "mandrel,"
which is to be laid on the side opposite the acute angle, or
AB, with its base coincident with the broader side, or AD; then
place the "inner envelope" paper pattern No.2, on
the top of the stiff paper with the side opposite the acute
angle, or AB, of the former about ¾ of an inch from the
acute angle, of CD of the latter, and role said envelope tightly
on the stiff paper and mandrel; after which slightly twist the
end that overlaps about 7/8 of an inch, or AC, and fold it into
the hollow at the base of the mandrel, making use of the point
of the "former," to close the folds and adapt the
paper to the cavity, which is to receive the point of the bullet,
being careful to secure the bottom of powder-case, so that no
powder can escape therefrom.
- Unite the bullet with the powder-case. Put the point of the
bullet well into the cavity of the powder-case, and place both
so fixed on the side of the "outer envelope" paper
opposite the acute angle, AB, and about ½ an inch from
the broader, or AC; roll the "outer envelope" tightly
round the bullet and powder-case, with the mandrel still in
it, the twist or fold the paper that overlaps, and tie it as
close as possible to the base of the bullet; after which place
the base of the cartridge on the table, and withdraw the mandrel
with care, by pressing the powder-case with one hand while raising
the mandrel with the other, so as not to separate the powder-case
from the bullet, both of which must be kept as close as possible
to prevent any play at the juncture, which would soon render
the cartridge unserviceable.
- Charge the powder-case. Place a funnel into the mouth of the
powder-case and pour 2½ drams of powder or a less quantity,
according to the arm used, into it; remove the funnel, being
careful that none of the powder escapes between the inner and
outer envelopes; and secure the charge by squeezing the tops
of the two envelopes close to the stiff paper of powder-case,
and giving them a slight twist with a pressure inwards, laying
the ends on the side of the cartridge. The slits in the outer
envelope are made to facilitate its detachment when fired.
- 4. Lubricate the cartridge. The cartridge being complete,
dip the base up to the shoulder of the bullet, in a mixture
composed of 5 parts of bees-wax and 1 part of tallow.
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