DIY mold for lead ingots

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I will be casting my own lead bullets, and even though Lee makes a very inexpensive ingot mold, I decided to make my own with leftover steel after seeing one in a youtube video recently.To give him credit for the idea, here is the original video that gave me the "inspiration":  I use left-over 1/4" angle iron for mine.  This is how two of the "scrap" pieces looked like before starting:The length I used was just about the height of my Lee 20 pound casting pot:and then lots of welding to make it "water tight".  Not my best work, but this should work fine for molten lead:Close-up on the back welds:I even gave the side facing the lead a coat of Moly Resin (should stand up to 1000F now that it is cured), to aid in the lead coming off the mold.  In this first photo you can also see the DIY smelting pot and handles I welded, also getting Moly Resin in my curing oven:I hope to try them this coming weekend to see how they turn out in actual use.Will
Reply:I did the same thing might want to smooth the welds in the bottom if the molds it makes it easier for the lead to pop out, nothing for it to grab onto.Miller 252 Mig w/Spool GunMiller Dynasty 350 TigMiller 225 AC-DC StickMiller Spectrum 875 PlasmaOxy/Acet.
Reply:One of the molds has no welding in the side facing the lead:the other I did weld the sides (I probably shouldn't have - part of the whole DIY and learning):I used the Moly Resin to try and prevent the lead from sticking - I don't know yet if it will work well or not.  I hope to report soon on this.
Reply:I've made large lead molds to cast V weights for scuba diving. I few things I've learned. Straight cuts on the sides can be problematic. If the piece bows in a tiny bit, the lead won't come out easily. By cutting the sides at an angle deliberately, you make the top larger than the bottom and avoid this issue.You may have trouble with both designs on the inside welds. The one without welds, the lead will want to fill the small area that is open and can lock in the lead when done. The one that was welded, the beads may give an area to lock in the welds. I welded the inside edges and tried as much as possible to make the welds concave ( used tig to have more control over this than mig in several cases.) Then I took a grinder or dremel tool and "carved" out the welds to make then concave and smooth out any areas that needed it..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Nice idea, years ago when i had access to a lot of lead i melted it down and poured them into brick recesses, gave them a right gold ingot look, especially if you sprayed it with gold paint
Reply:Good job but a lot of work.I reload also but am kind of lazy I guess. My wife gave me a cast iron cornbread cooker that has recesses shaped like an ear of corn and I bought it's twin at secondhand store for a buck. They make ingots that weigh about a pound like the store bought ones. PS: they don't stack as well as the semi-retangular ones.
Reply:It was very cold here in Texas (38F), but I got to try them today.It was so cold, and the molds so literally cold, that the lead solidified very fast:The ingots separated easily from the bottom (even the ones that were soldered on the inside - bottom 4x), BUT they got caught by the upper lip, the straight side.  I need to cut a relief on them, so that they can just drop free:Will
Reply:Nice looking work Will.   I should have known that you'd be into welding too.  Daniel
Reply:Originally Posted by dbstooNice looking work Will.   I should have known that you'd be into welding too.  Daniel
Reply:One trick is to preheat your molds by setting them out over the pot to warm up while your lead is melting. You'll want to do the same thing with your bullet molds or you'll have issues with your castings.Keep in mind lead is toxic. Good common sense and hygiene will go a long ways to avoiding issues. If working with "dirty" lead, a good respirator isn't a bad idea and stay out of the fumes and smoke  if at all possible.  Wash well after working with lead..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWOne trick is to preheat your molds by setting them out over the pot to warm up while your lead is melting. You'll want to do the same thing with your bullet molds or you'll have issues with your castings.Keep in mind lead is toxic. Good common sense and hygiene will go a long ways to avoiding issues. If working with "dirty" lead, a good respirator isn't a bad idea and stay out of the fumes and smoke  if at all possible.  Wash well after working with lead.
Reply:Originally Posted by wquilesGreat advice - thanks much
Reply:I used to melt lead sinkers on the kitchen range with my dad to cast lead soldier as a kid. ( Ah the good old days... when you could still give a kid toxic materials and molten metal to work with when they were in elementary school...)Best thing I have found to melt bulk lead is on old plumbers torch and pot. The ones that screw onto a special 20 lb propane cylinder with a vertical valve used to melt lead for doing lead and oakum.I have one of the newer versions that has a hose to connect to the 20 lb standard cylinder and it's no where near as nice as the older units I've used were..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSW ( Ah the good old days... when you could still give a kid toxic materials and molten metal to work with when they were in elementary school...)
Reply:It's not just the lawyers with chemistry sets. Last year I was watching a show on old toys and chemistry sets came up. A lot of the chemicals that used to be in most sets now are on the Homeland security list as prohibited. The show was interviewing a couple who bought and sold vintage chemistry sets as well as replacement supplies. Sure enough they got raided one night by the Feds and had about 1/2 their items seized. Too many could be used for bomb making and the quantities on hand exceeded the maximum you can have on hand..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I recently heard on TV about a kid building a science fair project. He legally aquired items to build a nuclear reactor. The reactor started to go into run away so he threw it in his moms car trunk and drove it away trying to figure out how to dispose. At 2am, police, pulled him over. He told them not to open the trunk. Kid was arrested, bomb squad called in. Everything was contained. The kid was not charged with a crime because everything was obtained legally.I hope the couple selling chem sets didnt get into any trouble. I had a few myself and toy stores used to sell replacement chemicals.
Reply:Originally Posted by DSWIt's not just the lawyers with chemistry sets. Last year I was watching a show on old toys and chemistry sets came up. A lot of the chemicals that used to be in most sets now are on the Homeland security list as prohibited. The show was interviewing a couple who bought and sold vintage chemistry sets as well as replacement supplies. Sure enough they got raided one night by the Feds and had about 1/2 their items seized. Too many could be used for bomb making and the quantities on hand exceeded the maximum you can have on hand.
Reply:Originally Posted by InsanerideLead tastes good and Mercury is fun to play with. When I was a kid, MATTEL_ Toys made hot plate molds to make your own spiders, cowboys and Indians. Chemistry sets where popular also but I can see lawyers nowadays would have a field day with those toys.
Reply:Originally Posted by InsanerideI recently heard on TV about a kid building a science fair project. He legally aquired items to build a nuclear reactor. The reactor started to go into run away so he threw it in his moms car trunk and drove it away trying to figure out how to dispose. At 2am, police, pulled him over. He told them not to open the trunk. Kid was arrested, bomb squad called in. Everything was contained. The kid was not charged with a crime because everything was obtained legally.I hope the couple selling chem sets didnt get into any trouble. I had a few myself and toy stores used to sell replacement chemicals.
Reply:Originally Posted by DSWIt's not just the lawyers with chemistry sets. Last year I was watching a show on old toys and chemistry sets came up. A lot of the chemicals that used to be in most sets now are on the Homeland security list as prohibited. The show was interviewing a couple who bought and sold vintage chemistry sets as well as replacement supplies. Sure enough they got raided one night by the Feds and had about 1/2 their items seized. Too many could be used for bomb making and the quantities on hand exceeded the maximum you can have on hand.
Reply:Originally Posted by HT2-4956I think you're talking about "The Nuclear Boy Scout".    http://en.wikipedia.org/wiki/David_Hahn
Reply:Originally Posted by InsanerideYes, thats him. I only recently heard about this.HT2, it appears you have more in common with Hahn and Admiral Rickover than just the Navy.I remember hearing Gordon_Liddy talking about saving bacon grease to use for dynamite_ during WWII. How common is that? And, you cant take shampoo or conditioner on airplanes.