We’ve done some bullet casting in the past, both for handgun bullets, and the large, heavy (400gr+) projectiles used with Black Powder Cartridge Rifles. We can say, unequivocally, that newbies should seek out the assistance of a skilled, experienced mentor, who is familiar with the important safety procedures that must be employed. Working with molten lead can be dangerous. And it also takes some skill to get good results (without visible casting flaws), particularly with very large bullets.
There are valuable resources that can help you get started with the casting process. Wolfe Publishing offers two DVDs that cover the bullet casting process from start to finish. Bullet Casting 101 takes you through the basics: showing you how to choose the correct alloy for your application, prep molds, maintain the optimal temperatures, and lube and size bullets. The important steps are laid out clearly. In addition, Bullet Casting 101 helps you select the right equipment and preferred molds for your particular application. (To create uniform rifle bullets that shoot accurately, you really do need high-quality molds.)
Wolfe Publishing offers a companion DVD, Casting Premium Bullets for Handguns, that covers more advanced techniques for high-volume pistol bullet production. This DVD covers both single-cavity molds and multiple-cavity “gang” molds. (Gang molds can be frustrating at first; it is harder to maintain perfect temp control and mold separation is more complex). The DVD also reveals the sources of most common casting flaws, and explains how to detect cracks, voids and other common problems.
You’ll save considerable time and effort if you really understand how to avoid common mistakes before you start pouring lead. And you’ll get the best results if you learn how to “blend” the optimal alloy for the job. Maintaining the right mold temperature is also critical for good results. These topics and more are covered in these two DVDs, priced at $20.00 each on Amazon.
Good Books about Bullet Casting
Along with these DVDs, there are some excellent print resources about bullet casting. Here are two good bullet casting books we recommend. Every serious bullet caster should own Lyman’s Cast Bullet Handbook, now in its 4th Edition. We also like Casting Premium Bullets for the Black Powder Cartridge Rifle by Paul Matthews (Wolfe Publishing).
We used the Matthews book to improve our cast bullets for a Pedersoli 45/70. Notably, with factory-made cast bullets, that rifle shot about 3″ groups at 100 yards. With custom cast bullets, accuracy was nearly twice as good. We were also able to choose a custom mold that produced bullets with a much higher BC, which helped with long-range matches.
Looking for a good load for a new rifle? Or perhaps you want to try a new powder and bullet combo for an existing rig. One of the best places to start for load data is Hodgdon’s online Reloading Data Center for pistol, rifle, and shotgun reloaders. Check out the Reloading Data Center at www.HodgdonReloading.com.
In the Data Center, you’ll find thousands of load recipes for pistol, rifle, and shotgun. Rifle shooters will find dozens of loads for their favorite Hodgdon, IMR, and Winchester powders such as H4198, H4895, Varget, H4350, and IMR 8208 XBR. And Hodgdon’s Reloading Center is “mobile-friendly” so it works well with smartphones and tables. Navigation is easy, and you can set the search criteria easily choosing your favorite powder or bullets. After choosing a cartridge, you can pre-select specific bullet weights and powder types. That quickly delivers just the information you want and need. You won’t have to scroll through scores of entries for bullets or powders you don’t use.
Mobile users will notice that the current Hodgdon Reloading Center is much more “user-friendly” for smart-phone and tablet users. Controls have been optimized for touch-screens, and buttons are large and easy to use. Likewise the results are displayed in a large, easy-to read format.
How to Get Started with Handloading
Getting started in Reloading? Ultimate Reloader offers a helpful introductory video that covers the basics. In addition, a recent Ultimate Reloader article reviews the types of reloading presses, plus the other gear you’ll need, from dies to powder dispensers.
At the request of our readers, we provide select “Deals of the Week”. Every Sunday afternoon or Monday morning we offer our Best Bargain selections. Here are some of the best deals on firearms, hardware, reloading components, optics, and shooting accessories. Be aware that sale prices are subject to change, and once clearance inventory is sold, it’s gone for good. You snooze you lose.
1. MidwayUSA — Hunting Gear — 29% to 56% Off
⏺ Get gear for your annual hunt while saving big
Hunting season is here. Grab those extra gear items you need before you head out into the backwoods on your hunt. At MidwayUSA you’ll find great hunting items at bargain prices right now. As shown above, here are some of our top hunting gear picks:
⏺ Many popular std and magnum calibers, awesome deal includes Vortex scope
Hunters take heed — with this deal you can grab a new deer rifle, complete with mounted Vortex scope, for under $350.00! Kentucky Gun Company is offering Thompson Center (T/C) Compass bolt-action rifles in .223 Rem, .243 Win, 6.5 Creedmoor, 7mm Rem Magnu, .308 Win, .30-06 Sprg, or .300 Win Magnum for only $396.97 (cash/check). That’s a killer deal by itself, but these rifles now qualify for a Thompson Center $50 Rebate. That lowers your net cost to just $346.97!
3. Bullet Central — Berger Bullets in Stock
⏺ Good prices on high-demand target bullets from Berger
With concerns over social disorder, reloading components have been harder to find. For you match shooters looking for quality bullets, head over to BulletCentral.com. There you’ll find a large selection of Berger target bullets in stock. Not only does Bullet Central has a large supply of Berger bullets, but the prices are about as low as you can find now. That’s a win-win.
4. Amazon — Vortex Diamondback HD Spotting Scope, $399.00
⏺ Great Spotting Scope Deal — hard to beat at twice the price
Whether hunting or target shooting, spotting scopes get you on target faster and easier than bare eyes or riflescope. If you need a good HD-grade spotter, check out the Vortex Diamondback HD 16-48x65mm angled spotting scope for $399.00. It offers great clarity and rock-solid lifetime guarantee. Relatively compact and weighing 49.8 ounces, this is a good choice for a hunter. There’s also a straight version for $399.00, with same 16-48X power and 65mm objective. If you need more magnification and low-light performance, Vortex offers the 20-60x80mm Diamondback HD spotter for $499.00.
5. Natchez — Big Savings on Nikon Hunting and Tactical Scopes
⏺ Incredible prices on a wide variety of FFP and SFP rifle scopes
Do you need a reliable scope with good controls and sharp glass, but you’re on a tight budget? Check out the Nikon scope sale at Natchez. You will find a wide variety of hunting and tactical scopes. Select the magnification level for your discipline. For PRS, you can save big on excellent FFP MRAD FX1000 scopes. There are also small AR scopes on sale. NOTE: Shown above are just three of the Nikon scopes on sale. There are dozens of other models and configurations discounted 30% to 60%, with 40% savings typical.
6. Midsouth — Norma .223 Remington Brass, $99.99 for 250
⏺ Impressive deal on very high quality .223 Rem brass
After Lapua, Norma makes some of the best brass you can buy. And here’s a chance to get a big supply of .223 Rem brass for your High Power or varmint rifle. This 223 Remington brass has very tight tolerances, holds up well to multiple reloads. We have seen very good accuracy with this brass with both light and heavy .224-caliber bullets. The price — $99.99 for 250 cases, works out to $0.39 per case. You can pay up to $0.70 per case for some other premium .223 Rem brass.
⏺ Take advantage of Browning Bucks Rebates up to $100
Browning makes excellent rifles, shotguns, and pistols. The Browning Buckmark is one of our favorite .22 LR rimfire pistol, and Browning Citori shotguns are renown for their build quality and performance. Right now CDNN Sports is discounting a wide selection of Browning Firearms. And now through the end of September 30, 2020, you can a Browning Bucks rebate — up to $100.00 on Citori shotguns. The rifle rebate is $50, while the pistol rebate is $25.00. Act soon before the rebate expires on 9/30/2020.
8. MidwayUSA — Pro Series Competition Shooting Mat, $32.99
⏺ Very high quality mat for the price — big discount
The MidwayUSA Pro Series Competition Shooting Mat is now on sale for just $32.99, 40% off the basic price. The Pro Series mat measures a full 73.5″ x 35.5″. Zippered pockets on the front flap hold ammo or log books. And there are webbing “pockets” for bipod feet so you can pre-load your bipod with forward pressure. This quality mat boasts 0.35″ thick padding, multiple pockets, 6 grommets for staking, and a nice carry strap. It’s easy to transport, rolling up to about nine inches in diameter. User reviews of this $32.99 Shooting Mat have been very positive.
9. Grafs.com — Peregrine MAGnet Gun Caddy, $5.99
Here’s a handy low cost item that can hold your rifle vertically on any steel surface. This works great on gun safes (outside or inside), and the MAGNet Gun Caddy can be used on vehicles too. The patented design makes it possible to secure and remove your gun from the holder with just one hand. The $5.99 MAGnet Gun Caddy is modular so you can arrange multiple units at whatever height works best. If your safe interior is carpet-lined, use the supplied Velcro to hold the MAGnet caddy in place.
With the big fires happening on the West Coast, many have wondered about hazards faced by gun owners in fire zones. This important video shows what really happens when loaded ammunition burns. You will probably be surprised. Contrary to Hollywood notions, the ammo doesn’t ignite in a massive explosion. Far from it… basically the rounds “cook off” one by one, and the bullets release at relatively low velocity. We’ve featured this SAAMI research project before, but it is worth reprising for those who have not yet seen the burn tests.
A few years back, SAAMI released an important video concerning ammo and fire. With professional fire-fighters standing by, over 400,000 rounds of ammo were incinerated in a series of eye-opening tests. If you haven’t had the chance to view this video yet, you should take the time to watch it now
The Sporting Arms and Ammunition Manufacturers’ Institute (SAAMI) has produced an amazing 25-minute video that shows what actually happens to sporting ammunition involved in a fire. This video shows the results of serious tests conducted with the assistance of professional fire crews. We strongly recommend you watch this video, all the way through. It dispels many myths, while demonstrating what really happens when ammunition is burned, dropped, or crushed.
Watch SAAMI Ammunition Testing Video
Video Timeline
2:10 Impact Test (ignited outside firearm)
3:40 65-foot Drop Test
5:08 Bullet Impact (.308 Win firing)
7:55 Blasting Cap Attacks
9:55 Bulldozer and Forklift Tests
12:20 Boxed Ammo Bonfire
15:37 Bonfire without Packaging
17:21 Retail Store Simulation Burn
20:55 Truck Trailer Burn
Over 400,000 rounds of ammunition were used in the tests. Some of the footage is quite remarkable. Testers built a bonfire with 28,000 rounds of boxed ammo soaked in diesel fuel. Then the testers loaded five pallets of ammo (250,000 rounds) in the back of a semi-truck, and torched it all using wood and paper fire-starting materials doused with diesel fuel.
The video shows that, when ammo boxes are set on fire, and ammunition does discharge, the bullet normally exits at low speed and low pressure. SAAMI states: “Smokeless powders must be confined to propel a projectile at high velocity. When not in a firearm, projectile velocities are extremely low.” At distances of 10 meters, bullets launched from “cooked-off” ammo would not penetrate the normal “turn-out gear” worn by fire-fighters.
We are not suggesting you disregard the risks of ammo “cooking off” in a fire, but you will learn the realities of the situation by watching the video. There are some amazing demonstrations — including a simulated retail store fire with 115,000 rounds of ammo in boxes. As cartridges cook off, it sounds like a battery of machine-guns, but projectiles did not penetrate the “store” walls, or even two layers of sheet-rock. The fire crew puts out the “store fire” easily in under 20 seconds, just using water.
Additional Testing: Drop Test, Projectile Test, Crush Test, Blasting Cap Test
Drop Test
The video also offers interesting ammo-handling tests. Boxes of ammo were dropped from a height of 65 feet. Only a tiny fraction of the cartridges discharged, and there was no chain-fire. SAAMI concludes: “When dropped from extreme heights (65 feet), sporting ammunition is unlikely to ignite. If a cartridge ignites, it does not propagate.”
Rifle Fire Test
SAAMI’s testers even tried to blow up boxes of ammunition with rifle fire. Boxes of loaded ammo were shot with .308 Win rounds from 65 yards. The video includes fascinating slow-motion footage showing rounds penetrating boxes of rifle cartridges, pistol ammo, and shotgun shells. Individual cartridges that were penetrated were destroyed, but adjacent cartridges suffered little damage, other than some powder leakage. SAAMI observed: “Most of the ammunition did not ignite. When a cartridge did ignite, there was no chain reaction.”
Bulldozer Crush Test
The test team also did an amazing “crush-test” using a Bulldozer. First boxes of loaded ammo, then loose piles of ammo, were crushed under the treads of a Bulldozer. A handful of rounds fired off, but again there was no chain-fire, and no large explosion. SAAMI observed: “Even in the most extreme conditions of compression and friction, sporting ammunition is unlikely to ignite. [If it does ignite when crushed] it does not propagate.”
Blasting Cap Test
Perhaps most amazingly, the testers were not able to get ammunition to chain-fire (detonate all at once), even when using blasting caps affixed directly to live primers. In the SAAMI test, a blasting cap was placed on the primer of a round housed in a large box of ammo. One cartridge ignited but the rest of the boxed ammo was relatively undamaged and there was no propagation.
Lyman has just released an expanded, updated Second Edition of its AR Reloading Handbook. The original handbook was the first reloading manual dedicated exclusively to the most popular semi-auto rifle in the USA. The Second Edition of this comprehensive Lyman AR Reloading Handbook has been updated to include more cartridge types and significantly more load data. This provides AR shooters with reloading info for the vast majority of popular chamberings used in AR-platform firearms. GET BOOK HERE.
Reloaders will appreciate the extensive pressure-tested data covering a very wide selection of bullet types and powder types. The Second Edition provided data for newer cartridges such as the .224 Valkyrie, .22 Nosler, .24 Nosler, 350 Legend, as well as sub-sonic data. In addition, articles by well-known authorities are included, covering topics such as “Building An AR” and “AR15 Gas System Lengths”. This book is available right now direct from Lyman and will soon be avialable through Amazon.
Features of Lyman AR Reloading Handbook (Second Edition)
— Reloading data for popular AR-platform cartridge types, including the .223 Rem, .224 Valkyrie, 6.8 Rem, .300 AAC, 7.62×39, 350 Legend, 450 Bushmaster, .50 Beowulf and more.
— Many informative articles on specialty topics such as Reloading for Suppressors and Building ARs.
— Load Data covers all major brands of bullets and powders.
— Load Data for cast bullet data and sub-sonic loads.
AR-Platform Insights — Operation and Maintenance Tips
Here are two helpful videos for AR owners. The first uses 3D computer animation to show how AR-platform rifles work — from the inside. The Cutaway views show the operation of the gas system and bolt while cycling. The second video, by legendary competitive shooter Jerry Miculek, provide helpful guidance on AR disassembly and maintenance.
Book publishing tip from EdLongRange. We welcome reader submissions.
If you buy one book about Long Range Shooting, this should be it. Based on sophisticated testing and research, this 356-page hardcover from Applied Ballistics offers important insights you won’t find anywhere else. Modern Advancements in Long Range Shooting – Volume II, the latest treatise from Bryan Litz, is chock full of information, much of it derived through sophisticated field testing. As Chief Ballistician for Berger Bullets (and a trained rocket scientist), author Bryan Litz is uniquely qualified. Bryan is also an ace sling shooter and a past F-TR National Champion. Moreover, Bryan’s company, Applied Ballistics, has been a leader in the Extreme Long Range (ELR) discipline.
AUDIO FILE: Bryan Litz Talks about Modern Advancements in Long Range Shooting, Volume 2. (Sound file loads when you click button).
Volume II of Modern Advancements in Long Range Shooting ($39.95) contains all-new content derived from research by Applied Ballistics. Author Bryan Litz along with contributing authors Nick Vitalbo and Cal Zant use the scientific method and careful testing to answer important questions faced by long range shooters. In particular, this volume explores the subject of bullet dispersion including group convergence. Advanced hand-loading subjects are covered such as: bullet pointing and trimming, powder measurement, flash hole deburring, neck tension, and fill ratio. Each topic is explored with extensive live fire testing, and the resulting information helps to guide hand loaders in a deliberate path to success. The current bullet library of measured G1 and G7 ballistic coefficients is included as an appendix. This library currently has data on 533 bullets in common use by long range shooters.
Bryan tells us that one purpose of this book is to dispel myths and correct commonly-held misconceptions: “Modern Advancements in Long Range Shooting aims to end the misinformation which is so prevalent in long range shooting. By applying the scientific method and taking a Myth Buster approach, the state of the art is advanced….”
Bullet Dispersion and Group Convergence
Part 1 of this Volume is focused on the details of rifle bullet dispersion. Chapter 1 builds a discussion of dispersion and precision that every shooter will benefit from in terms of understanding how it impacts their particular shooting application. How many shots should you shoot in a group? What kind of 5-shot 100 yard groups correlate to average or winning precision levels in 1000 yard F-Class shooting?
Chapter 2 presents a very detailed investigation of the mysterious concept of group convergence, which is the common idea that some guns can shoot smaller (MOA) groups at longer ranges. This concept is thoroughly tested with extensive live fire, and the results answer a very important question that has baffled shooters for many generations.
Part 2 of this Volume is focused on various aspects of advanced hand-loading. Modern Advancements (Vol. II) employs live fire testing to answer the important questions that precision hand loaders are asking. What are the best ways to achieve MVs with low ES and SD? Do flash hole deburring, neck tension, primer selection, and fill ratio and powder scales sensitivity make a difference and how much? All of these questions are explored in detail with a clear explanation of test results.
One of the important chapters of Part 2 examines bullet pointing and trimming. Applied Ballistics tested 39 different bullet types from .224 through .338 caliber. Ten samples of each bullet were tested for BC in each of the following configurations: original out of the box, pointed, trimmed, pointed and trimmed. The effect on the average BC as well as the uniformity in BC was measured and tabulated, revealing what works best.
Part 3 covers a variety of general research topics. Contributing author Nick Vitalbo, a laser technology expert, tested 22 different laser rangefinders. Nick’s material on rangefinder performance is a landmark piece of work. Nick shows how shooters can determine the performance of a rangefinder under various lighting conditions, target sizes, and reflectivities.
Chapter 9 is a thorough analysis of rimfire ammunition. Ballistic Performance of Rifle Bullets, 2nd Edition presented live fire data on 95 different types of .22 rimfire ammunition, each tested in five different barrels having various lengths and twist rates. Where that book just presented the data, Chapter 9 of this book offers detailed analysis of all the test results and shows what properties of rimfire ammunition are favorable, and how the BCs, muzzle velocities and consistency of the ammo are affected by the different barrels.
Chapter 10 is a discussion of aerodynamic drag as it relates to ballistic trajectory modeling. You will learn from the ground up: what an aerodynamic drag model is, how it’s measure and used to predict trajectories. Analysis is presented which shows how the best trajectory models compare to actual measured drop in the real world.
Finally, contributing author Cal Zant of the Precision Rifle Blog presents a study of modern carbon fiber-wrapped barrels in Chapter 11. The science and technology of these modern rifle barrels is discussed, and then everything from point of impact shift to group sizes are compared for several samples of each type of barrel including standard steel barrels.
At the request of our readers, we provide select “Deals of the Week”. Every Sunday afternoon or Monday morning we offer our Best Bargain selections. Here are some of the best deals on firearms, hardware, reloading components, optics, and shooting accessories. Be aware that sale prices are subject to change, and once clearance inventory is sold, it’s gone for good. You snooze you lose.
1. MidwayUSA — Vortex Viper Scope Scale, under $300
⏺ Huge discounts on Vortex Vipers with lifetime warranty
Need a scope for that hunting rifle or varmint rig? Here are two great deals on quality Vortex Viper scopes. For a deer rifle choose the 2.5-10x44mm Viper HS scope priced at just $249.99 — a 39% savings. This scope weighs just 16.5 ounces — that’s important on a hunting rig you’ll carry all day long. For varminting duties, where you need more magnification, there’s a 6.5-20x44mm Vortex Viper on sale for just $299.99, that’s 30% off. Either way you get a good scope with superb Vortex lifetime warranty for under $300.00.
2. Bullet Central — Berger Bullets in Stock
⏺ Good prices on high-demand target bullets from Berger
With concerns over social disorder, reloading components have been harder to find. For you match shooters looking for quality bullets, head over to BulletCentral.com. There you’ll find a large selection of Berger target bullets in stock. Not only does Bullet Central has a large supply of Berger bullets, but the prices are about as low as you can find now. That’s a win-win.
Who doesn’t love a good waterfowl hunt? It’s a great outdoor escape that can put food on the table. Right now Sportsman’s Warehouse is offering a quality waterfowl shotgun at a great price. The Winchester SXP Waterfowl Hybrid Hunter in 12ga or 20ga is on sale now for just $354.99. These well-made, 3-1/2″-shell-capable shotguns feature an ultra-tough Mossy Oak and Permacote protective finish.
⏺ Wireless photos and videos, good controls, USB Charging
In the quest for better borescope performance, manufacturers are improving their electro-optics offerings. At the forefront is Lyman, the company that pioneered the affordable, digital borecam. Lyman has released its new Borecam PRO 24″ wireless borescope. This boasts wireless WiFi operation, 720P resolution for sharp images, and adjustable light intensity. The BoreCam Pro has a 24″ long rod that will fit all .20 caliber and larger-diameter barrels. The Borecam PRO takes photos and video with the push of a button and has easy to use Apps for iOS and Android mobile devices.
5. Amazon — WIREGEAR Gunsmith Punch Set, $39.99
⏺ Versatile punch set performs multiple gun tasks
When working on firearms and removing or assembling component, you definitely need a good set of precision punches to keep from damaging anything. We found this great WIREGEAR Gunsmith Punch Set that even comes with a punch block too. With this punch set you can feel confident that you can remove any pin without harming your finish or damaging holes.
6. Palmetto State Armory — Taurus G2c 9mm Pistol, $299.99
⏺ Good CCW 9mm carry pistol for under $300.00
Right now compact 9mm carry guns are in very high demand. Many gun vendors have limited inventory and have raised prices. Here’s a good little compact carry gun at an attractive price — half what you might pay for a 9mm Glock 19 these days. Palmetto State Armory has the black-on-black Taurus 9mm G2c for just $184.99. This affordable 9mm handgun is a true compact, 6.25″ OAL, and weighing just 21.2 oz. unloaded. Despite its small size, the G2c has a 12-round magazine. We like the fact it has a left-side manual safety (unlike the Glock).
7. Graf & Sons — MTM Promotion FREE Patch Catcher
⏺ Buy $40 of handy MTM containers, get FREE Patch-Catcher
Right now, if you buy at least $40 of MTM products at Grafs.com you can get a FREE MTM Patch Catcher or Hat. The patch catcher is great and allows you to keep all your soiled patches off your bench or table and easily throw them away. Trust us, you’ll find it easy to get your money’s worth for the $40 purchase — MTM makes high quality ammo carriers, range boxes (with cleaning cradles), pistol storage boxes, ammo crates, cleaning rod carriers, bore guides, and compact rests. We use and recommend MTM range boxes and MTM ammo carriers.
⏺ Inexpensive, ultra-lightweight gun support — good for sight-in or ARs
If you’re tired of carrying heavy sandbags to rest your guns, consider a new alternative. The BenchMaster Weapon Rack XBlock Gun Rest costs less than $20 and weighs just 7.1 ounces! Sized 8″ x 6″ x 4″, it can be used in multiple ways to support your firearms. Made from lightweight, high-density foam, this rest is impervious to moisture and mildew. This XBlock is a good inexpensive option for sighting in a deer rifle before your annual hunt. Or keep an XBlock behind your truck seat as an “anytime” rest. BenchMaster also makes an adjustable 3-section Bench Block Gun Rest ($27.99) that works well with ARs.
9. Amazon — Hornady One Shot, $9.99
⏺ Dry-Film Lube — not sticky, easy to apply, used by top shooters
If you’re looking for a mess-free way to lube cases before sizing give Hornady One Shot a try. Get 7 oz. can for $9.99, or 14 oz. can for $13.99. It’s easy to apply and leaves a grease-free, friction-reducing film that works great for full-length case sizing. Here’s a good video that shows application methods with tips to ensure great results with your brass.
Here’s something you’ve never seen before — a full-size rifle chambered for the tiny 7.62×25 Tokarev round. This rifle was a fun project by Les E., aka “scasa” in our AccurateShooter Forum. This is a true “home-built” rifle. Les machined the action himself (receiver AND bolt), chambered the barrel, and crafted the stock from a blank. You’ll find complete build details (with machining photos) in this Forum Thread.
Why did Les build this unique rifle? He tells us: “I just thought it would make a nice little rifle cartridge with light bullets and subsonic with heavier ones. D.J. Jones had something similar as the ‘Mini Whisper’.”
Les designed and built the action and bolt to fit the tiny 7.62×25 Tokarev cartridge. He told us: “Once upon a time I got this idea to make a bolt action with front locking lugs, full diameter bolt, Remington trigger. It took me years to get it all figured out and make all the tooling, then it took about six months to build the gun”. The rifle features a 1:10″-twist Adams & Bennett barrel that Les chambered himself.
Les designed and crafted the receiver and bolt assembly himself. The bolt features an extractor but not an ejector — the empty case stays on the end of the bolt. The extractor slot cuts through one lug, but Les says it still has 10 times the required strength.
Details of Action Design and Machining
Les explained: “The action started as a piece of 4160 bar stock. I drilled and reamed all the holes in my 12×36 Craftsman lathe. Cutting the slot inside for the locking lugs to pass through was the most difficult part. There were no blueprints for this and just a couple of sketches to get the slots right for the bolt handle slot and extraction cams. Everything is design on the fly. I used a grade 8 bolt for the bolt which did not require any hardening, they’re pretty hard already. Although I did make several receivers before I got it figured out, I only made one bolt.”
Surprisingly, Les is not a machinist by trade. He is just a very smart guy who learned by doing: “I’ve never had any machinist training. I mostly learned by trying different things until I found what works.”
NOTE: Under Federal law, it is legal to build an action or complete rifle for personal use (not for resale). Refer to ATF Regulations.
As you might expect, this cartridge is naturally pretty quiet. Les says it “makes less noise than a .17 HMR”. Recoil is also minimal. In a 9-lb rifle (with scope), shooting free recoil, the rifle moves only about three inches. Considering this is a tiny pistol cartridge, the accuracy is pretty good, as you can see:
Loading for the 7.62×25 Tokarev in a Rifle
The cartridge brass comes from Sellier & Bellot pistol ammo. Les currently loads with AA #7 and AA #9 powders, but he may try some others. His favorite load so far has Hornady 168gr A-Max bullets pushed by AA #9 powder and CCI 400 primers. This produced a 0.437″ group at 50 yards.
How does Les like the cartridge? He says: “I wish the 7.62×25 had a longer neck. At 0.140″ it’s pretty short. I think a longer neck would help getting things lined up better.” He notes that boat-tail bullets seem to load easier than flat-base projectiles.
Ammo is loaded with inexpensive Lee dies: “I’m using Lee dies and they seem to work OK. I’d like a better seater die and I may modify this one.”
Les reports: “The 168gr Berger moly LTB didn’t do as well as the 168gr A-Max so I started working with the A-Max. I’m loaded really long and the Tokarev evidently has a pretty long freebore but I managed to get it into the lands. The target photo above is the best this gun has ever shot. I’ve gotten mostly two-inch groups at 50 yards (my max home range distance). Recently I made some progress. My best group was a little less than 1/2 inch at 50 yards.”
Special Features of the Stock
Les built the stock himself from a laminated blank. For this project, Les added some interesting features to the stock. He created his own adjustable cheekpiece using all home-crafted hardware.
Les also fitted a barrel tension adjustment system in the stock to help tune the barrel harmonics. There is a hex-head machine screw in the bottom of the stock for adjusting the upward tension on the barrel.
Les crafted this stock with a thumbhole pattern with finger grooves. He has used this design on other stocks he has built as he likes the look and “feel”.
Here’s the super-speedy way to turn case-necks. Our friend Erik Cortina figured out how to turn his match cartridge case-necks using his milling machine. Erik told us: “While in Raton [a while back], Mid Tompkins told me that he turns his brass on milling machine. He said he could do about 500 in two hours, so I decided to try it.”
Erik fitted a Don Nielson “Pumpkin” neck-turner to the mill, and he used a modified 21st Century case holder to secure the brass. As you can see from this video, Erik was very successful with the process. The tool spins at 1500 rpm, turning Lapua 6.5-284 cases that have been necked up to 7mm.
Video Shows Eric Cortina Neck-Turning Cases with Milling Machine:
Cartridge Brass: Lapua 6.5-284 necked up to 7mm
Lubricant: Lithium grease inside and outside of neck
Neck-Turner: Nielson Pumpkin running at 1500 RPM
It’s hard to argue with Erik’s results. Here are his turned Lapua cases, which have neck-wall thickness consistent to two ten-thousandths of an inch. Think you could do better turning manually?
Some of Erik’s Facebook friends had questions about this process:
Q: Who makes the shell-holder?
Erik Cortina: I did! The shell-holder you can get from 21st Century. I Tig-welded a punch as a handle.
Q: I love the idea of working smarter not harder! Any galling issues? What are your mitigation techniques?
Erik Cortina: No issues. I use lithium grease in spray can. Makes a foam that I dip necks into.
Q: Shouldn’t either the case or the cutter be floating to allow most precise neck turning?
Erik Cortina: Up until [I tried this] I believed the same thing. I was going to build a floating case holder but decided to try rigid setup on a few cases before I built it. Results were great. Neck thickness doesn’t vary more than .0002″, which is same as when I was doing it with floating case holder on the lathe.
Q: Any problems with the Pumpkin changing the cut as it heats up?
Erik Cortina: No — there were no issues with that.
NOTE: Erik Cortina is a very skilled machinist who custom-crafted fittings used for this process. This kind of neck-turning with a milling machine may not be for the everyday hand-loader!
Nielson “Pumpkin” Neck-Turner
The circular orange cutting fixture on Erik’s Milling Machine is a Don Nielson “Pumpkin” neck-turning tool. Don designed this tool to be used by hand or with power. The Pumpkin boasts an eccentric mandrel that allows the cut to be adjusted easily in precise .0001″ increments. Benchresters like this as it allows for very precise control of cut depth and neck-wall thickness.
Nielson Neck Turner with carbide mandrel. Photo Courtesy Butch’s Reloading.
Here’s an inexpensive product that can make your case prep and loading tasks easier. We use and recommend the cleverly-designed Lyman Bleacher Blocks. These multi-level (stepped) cartridge holders save space on your bench AND make it easier to select a particular case/cartridge from a full block. Each row is a different height for convenience. With Bleacher Blocks it’s also easier to check for powder levels, or place bullets before the seating process.
Lyman’s Bleacher Block cartridge holders have many advantages over conventional, single-level blocks. Use the different levels for sorting brass. Or, migrate the brass from top to bottom as you proceed through case prep stages. If you are assembling loads with different bullets for load testing, you could arrange the loaded rounds on different levels for easy recognition. For example put V-Max loaded rounds on the top tier, and Berger Hybrid loaded rounds on the bottom tier. Or, if you are experimenting with neck tension, you can use different rows for cases processed with different bushings.
Made of durable orange polymer, Lyman Bleacher Blocks are molded in three sizes. The smallest size (with 0.388″-diam holes) fits .223 Rem-size case heads. The middle size (with 0.485″-diam holes) fits .308 Win-size case heads. That works for 6mmBR/Dasher sized cases perfectly. The biggest Bleacher Block has 0.565″-diameter recesses for magnum-size cases. All three cartridge block sizes hold fifty (50) rounds. Purchase any size for just $6.14 per Block at Midsouth.
Here’s what Lyman says about its innovative cartridge block design: “Our [stepped] loading blocks allow for easier handling of cases in and out of the loading block. Our stepped design allows you to easily grip a single case without jamming your fingers down into a group of cases like in traditional loading blocks, and allows for a smaller ‘footprint’ on your bench.”
Lyman Bleacher Blocks are among the Reloading Tools reviewed in this helpful video:
Wolfe Publishing offers a companion DVD, Casting Premium Bullets for Handguns, that covers more advanced techniques for high-volume pistol bullet production. This DVD covers both single-cavity molds and multiple-cavity “gang” molds. (Gang molds can be frustrating at first; it is harder to maintain perfect temp control and mold separation is more complex). The DVD also reveals the sources of most common casting flaws, and explains how to detect cracks, voids and other common problems.
The Sporting Arms and Ammunition Manufacturers’ Institute (
We are not suggesting you disregard the risks of ammo “cooking off” in a fire, but you will learn the realities of the situation by watching the video. There are some amazing demonstrations — including a simulated retail store fire with 115,000 rounds of ammo in boxes. As cartridges cook off, it sounds like a battery of machine-guns, but projectiles did not penetrate the “store” walls, or even two layers of sheet-rock. The fire crew puts out the “store fire” easily in under 20 seconds, just using water.
Part 2 of this Volume is focused on various aspects of advanced hand-loading. Modern Advancements (Vol. II) employs live fire testing to answer the important questions that precision hand loaders are asking. What are the best ways to achieve MVs with low ES and SD? Do flash hole deburring, neck tension, primer selection, and fill ratio and powder scales sensitivity make a difference and how much? All of these questions are explored in detail with a clear explanation of test results.
Here’s something you’ve never seen before — a full-size rifle chambered for the tiny 
The cartridge brass comes from Sellier & Bellot pistol ammo. Les currently loads with AA #7 and AA #9 powders, but he may try some others. His favorite load so far has Hornady 168gr A-Max bullets pushed by AA #9 powder and CCI 400 primers. This produced a 0.437″ group at 50 yards.
