Casting your own bullets at home is one of the most rewarding aspects of the reloading hobby. You gain control over quality, reduce your cost per round significantly, and develop a skill that serious shooters have practiced for generations. This guide walks you through everything you need to get started.
Quick summary: Home bullet casting requires a heat source, a lead alloy, a mold, and a way to size and lubricate the finished bullet. With the right equipment, a hobbyist can cast several hundred bullets per hour.
The economics are compelling. Commercial cast bullets can run $0.10–$0.20 each. When you cast your own from reclaimed lead, your cost drops to pennies per bullet — sometimes less than $0.02 each once you have your setup running. For high-volume shooters going through thousands of rounds per year, this adds up quickly.
Beyond cost savings, casting gives you control. You choose the alloy hardness, the bullet weight, and the profile. Competitive shooters often cast custom weights that aren't available commercially.
A bottom-pour electric furnace is the standard choice for home casting. It maintains a consistent temperature and lets you fill molds quickly without ladling. Look for a unit that holds at least 10 pounds of alloy and has a temperature control dial. Bottom-pour furnaces run $80–$150 for a basic unit.
Molds come in aluminum, iron, and brass. Aluminum molds heat up fast and are lightweight — good for beginners. Iron and brass molds hold heat more consistently and last longer under heavy use. Most molds cast 2–6 bullets per pour. Choose a mold designed for the caliber and bullet weight you want.
Pure lead is too soft for most applications. The most common alloys are:
After casting, bullets need to be sized to exact diameter and lubricated. A lubricator-sizer press handles both. Proper sizing ensures the bullet fits your barrel correctly. Lubrication reduces leading and extends barrel life.
Working with molten lead requires respect. Always wear eye protection and heat-resistant gloves. Cast in a well-ventilated area — lead fumes are a serious health hazard. Keep water away from molten lead; even small amounts of moisture can cause violent spattering.
| Problem | Likely Cause | Fix |
|---|---|---|
| Wrinkled bullets | Mold too cold | Preheat mold longer before casting |
| Frosted appearance | Lead too hot | Lower furnace temperature |
| Voids or cavities | Filling too slowly | Open spout fully, fill quickly |
| Bullets sticking in mold | Mold needs smoke | Smoke mold cavities with a lighter flame |
| Leading in barrel | Alloy too soft or no lube | Harden alloy or check lubrication |
Manual casting with a two-cavity mold produces around 100–150 bullets per hour for most hobbyists. That's fine for occasional use, but shooters going through 500–1,000 rounds per week quickly find manual casting to be a bottleneck.
Automated bullet casting machines solve this problem. A production casting machine can output 300–600+ bullets per hour with consistent quality and far less physical effort. The operator loads alloy, sets temperature, and the machine handles the fill, cool, and eject cycle automatically.
The M2R Automatic Casting Machine produces consistent, high-quality cast bullets with minimal operator effort — ideal for serious hobbyists and small manufacturers.
View the M2R MachineYes, in the United States it is legal for individuals to cast their own bullets for personal use. Always check your local and state regulations, as rules can vary.
Hardness depends on velocity. As a general rule, harder alloys are needed for higher velocities. Wheel weight alloy (around 12 BHN) works well for most handgun loads up to 1,000 fps. For rifle loads above 1,500 fps, a harder alloy like Linotype is advisable.
Pure lead is very soft and works for low-velocity loads like black powder and some cowboy action loads. For most centerfire cartridges, alloying with antimony and/or tin provides necessary hardness and better mold-filling characteristics.
Common sources include wheel weights (check with tire shops), plumbing supply stores, scrap metal dealers, and online lead suppliers. Always remelt and flux your alloy before casting to remove impurities.