The .45 ACP is one of the most satisfying cartridges to reload — and one of the most economical to cast bullets for. The large diameter and relatively low operating pressure make it forgiving to work with, and the heavy bullets cast quickly from common alloys. Whether you shoot 1911s, Glocks, or competition pistols, this guide covers .45 ACP bullet casting from start to finish.
Standard .45 ACP cast bullets are sized to .452" diameter. Some barrels, particularly older 1911s, may have looser bores and benefit from .453". Always slug your barrel and size accordingly — a properly fitted cast bullet is the foundation of good accuracy and minimal leading.
| Bullet Weight | Common Profile | Typical Use |
|---|---|---|
| 185 grain | Semi-Wadcutter, Hollow Point | Target shooting, competition |
| 200 grain | Semi-Wadcutter, Round Nose | Most popular competition weight |
| 225 grain | Round Nose, Flat Point | General purpose, cowboy action |
| 230 grain | Round Nose Ball | Standard weight, matches military spec |
The .45 ACP operates at relatively modest pressures (around 21,000 PSI) and velocities (830–1,000 fps for standard loads). This means you have flexibility with alloy selection — you don't need a hard alloy, but harder is generally better for reducing leading.
The .45 ACP advantage: Because of its large bore diameter and moderate pressure, the .45 ACP is one of the most forgiving cartridges for cast bullet use. Many shooters who struggle with leading in 9mm have no issues at all with .45 ACP cast loads.
The semi-wadcutter (SWC) is the classic .45 ACP cast bullet profile — a flat-nosed bullet with a sharp shoulder that cuts a clean hole in paper targets. It's the preferred choice for bullseye competition and general target shooting.
Round nose designs feed more reliably in some semi-automatics, particularly guns with tight feed ramps. If you're having feeding issues with SWC bullets, try a round nose flat point (RNFP) which offers a compromise between the clean-cutting flat nose and reliable feeding geometry.
Proper lubrication is essential for preventing leading and maintaining accuracy. The large grease grooves of a typical .45 ACP cast bullet hold substantial lube — use a quality bullet lubricant appropriate for your velocity range. Harder lubes work better at higher velocities; softer lubes are fine for target loads.
For those shooting suppressed .45 ACP, a high-quality lube is especially important as suppressors run at elevated temperatures.
The .45 ACP's large bullet diameter means each bullet contains more alloy than a 9mm bullet — roughly twice as much lead per bullet. At scale, this matters both for furnace capacity and cycle time. A high-volume shooter going through 500 rounds of .45 ACP per week needs to cast 2,000+ bullets per month.
Manual casting with a two-cavity mold produces roughly 80–120 .45 ACP bullets per hour — slower than 9mm because of the longer fill time per cavity. An automated casting machine dramatically changes this equation, maintaining consistent output without operator fatigue.
The M2R Automatic Casting Machine handles .45 ACP and dozens of other calibers. Consistent quality, high output, minimal operator effort.
View the M2R MachineStart at .452" — this is standard for most modern .45 ACP barrels. Slug your barrel by pushing a soft lead ball through it and measuring the recovered diameter. Size your bullets .001" over groove diameter for best results.
Absolutely. The 1911 was originally designed for lead bullet use and handles cast bullets very well. Feed ramp geometry on most 1911s is well-suited to round nose and semi-wadcutter profiles.
Leading in .45 ACP is most commonly caused by undersized bullets, insufficient lubrication, or an alloy that's too soft for your velocity. Check your sizing diameter first, then evaluate your lube. If leading persists, try a slightly harder alloy.
Cast .45 ACP bullets from commercial sources typically run $0.08–$0.15 each. Casting your own from wheel weight alloy, the cost drops to $0.03–$0.05 per bullet once your equipment is paid off — primarily just the cost of alloy. Over 10,000 rounds, that's a savings of $500–$1,000.