This was a post started by Randy on 12/11/2004

OK, Stan "made me do it"! A while back, Stan asked if I'd submit a ditty on bullet making - since the pic posting is now "legal", we decided to use the  more effective "picture is worth a few words" version . . .  after receiving and unpacking, this is the first step in making BR quality bullets. This spool of .250" diameter lead wire will be cut into aproximately 130 pieces, each about thirty-inch long. R.G.

Now, here's a really neat machine built by my Uncle and BIG MIKE

Here's a close up of the business end of the core cutter

a clever design, which, using recorded micrometer settings, allows us to get very repeatable length when changing through the length/weight cycle! R.G.

And here's a closer look at the just cut cores . . .

 A little Q & A ensued.

Stan Ware:  Randy, a post or two back you said the cores were cut into 30inch lengths first and straightened. Why do you cut to 30inch lenghts ? What is the reason for this ? Why don't you cut into 1 inch pieces from roll ?.... Dumb question... but I don't know.

Randy: Stan, the wire is cut into 30" lengths (sticks) and then straightened, following which it is fed into the core cutter and cut into the individual individual "cores" - I probably used the wrong terminology. If you look at the previous core cutter pic, you'll see a stick of lead wire sticking up -it's toward the right hand end of the contraption. The cut cores are also "ejected" by gravity - the white "tickler" brushes the cores as the slide moves forward and dislodges the core from the cutter bushing. R.G.

GregP:  Randy,
How do you strighten the 30" sticks? Roll them between metal or hardwood plates? Tks --greg

Randy:  Greg, BIG MIKE may "kill" ME for letting out the secret . . . WE "roll" the wire between an aluminum plate, which is equipped with handles, and the "plate" which you can see in the pic of cutting the wire. The straightening is REALLY a DRAG! :(  Eventually, we will have the new cutter hooked up to a "feeder/straightener" and the wire will be cut into core slugs right off the roll! Well, that's the DREAM! R.G

Jim Saubier:  how much of a nub do you use at the end of the 30" section.  i imagine that every section you will lose a little from the feed end.  your cutter looks real slick, we are using the manual deal and it isn't quick by any means.

 Randy:  Jim, Since I cut all of the sticks using diagonal-cutting pliers, the ends are, indeed, waste. However, Only about 1/8th inch on the beginning end - the  final core may be too  short. I have attached a pic of my old reliable CH cutter (it was part of the "deal" when I scored my first set of dies  - a GREAT set of Rorschach .22 Cal.); I still use this cutter for 22 and 6mm cores . . . and occasionally, an odd lot of thirties. AS with the cutter my Uncle and I dreamed up and built, the CH cuts very square ends which are free of bulges and/or flaring - this makes squirting much more user friendly! 

Using the CH, BIG MIKE can only cut about 50% of what he cruises at using the new cutter! But since I put it close to the tube, he's much happier! ;) R.G.

Some Comments

K. Skjerdal:  With the cost of the lead and the jackets, and then all the hard work to form the lead into cores and point things up, (your press forearm must be getting HUGH by now and we will have to start calling you Popeye), plus the cost of maintaining the shop, the equipment, buying new point up dies and new bases, cleaning and lube supplies, drying towels, and on and on, at $240/1000, your bullets are the best bargin in BR!

Wait, what the hell I'm I tell this to you for, you are going to start charging us more...

Randy: Keith, thank you for your kind words. THis is true of even my friendly competitors bullets: hand swaged BR quality bullets are a REAL deal - I can't remember the last time I saw any of the Name Brand bullets at the TOP of an equipment list! R.G.

Jim Saubier:  thanks Randy.  We use the same spools of Star lead on a rack suspended from the ceiling.  we have a bench set up that is 6' long with the cutter on the end of the table.  We pull off sections from the spool, straightening, wiping crud from the wire and then cutting.  We used to do it in sections but always had a nub at the end.  Our cutter is a very simple cutter from Niemi, but is certainly not as efficient or fast as it could be. It is neat to see how others are doing things.  i've only seen 2 other set-ups for bullet besides our own.  Seems that everybody develops their own way of doing certain tasks.  If I had to make the number of bullets that you do, i'd sure want to automate any of the process' that i could.  I don't see the demand for .30 caliber bullets slowing any time soon.