Here’s a really great video about firearms crafting produced by Beretta, a legendary Italian gun-maker founded in 1526 — nearly 500 years ago. This movie, entitled “Human Technology”, is one of most impressive videos we’ve ever featured on this site. It’s that good. You’ll see an amazing blend of modern technology along with old-world artisanship — “a mesmerizing meld of the high-tech and the traditional”. (Daniel Xu, Outdoor Hub.)
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“Human Technology is a singular and symbolic movie, its cast entirely made up of Beretta workmen, thus illustrating the perfect synthesis between craftsmanship and technology,” Beretta writes. This artistic movie by Ancarani Studio illustrates all the aspects of the manufacturing of a high-end Beretta shotgun. This video is a study in contrast. The movements of robotic assembly machines are juxtaposed with the centuries-old craftsmanship of stock carvers. Beautifully filmed and edited, this video should amaze and entertain anyone who loves fine firearms. (Full-screen HD Recommended.)
Beretta — Incredible history. Beretta was founded in 1526, almost five centuries ago. Remarkably, the enterprise is still owned by the Beretta family.
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Here’s a really great video about firearms crafting produced by Beretta, a legendary Italian gun-maker founded in 1526 — nearly 500 years ago. This movie, entitled “Human Technology”, is one of most impressive videos we’ve ever featured on this site. It’s that good. You’ll see an amazing blend of modern technology along with old-world artisanship — “a mesmerizing meld of the high-tech and the traditional”. (Daniel Xu, Outdoor Hub.)
“Human Technology is a singular and symbolic movie, its cast entirely made up of Beretta workmen, thus illustrating the perfect synthesis between craftsmanship and technology,” Beretta writes. This artistic movie by Ancarani Studio illustrates all the aspects of the manufacturing of a high-end Beretta shotgun. This video is a study in contrast. The movements of robotic assembly machines are juxtaposed with the centuries-old craftsmanship of stock carvers. Beautifully filmed and edited, this video should amaze and entertain anyone who loves fine firearms. (Full-screen HD Recommended.)
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There are many reasons you might want to make a chamber cast. You may have acquired an older rifle and need to verify the chamber dimensions. Or, if you have a new reamer, you may want to check the exact “cut” dimensions against the blueprint specs. A chamber casting is also valuable if you run across a firearm that you believe has a custom barrel on it and you want to find out the dimensions of the chamber. Lastly, you may want to prepare a chamber casting to be used in the making of custom dies. (Most reloading die makers know how to work from Cerrosafe chamber casts.)
Cerrosafe is a metal alloy that has some unique properties which make it ideal for chamber casting. First, it has a relatively low melting point of 158 to 190° Fahrenheit. This makes it easy for the handloader to melt the Cerrosafe in his home shop. Second, it shrinks slightly during cooling which allows it to be extracted from the chamber easily. It then re-expands to the chamber’s original size after about one hour at room temperature. After cooling for about 200 hours, the chamber cast will expand to about .0025″ larger than the actual chamber size.
One of our Forum members has done many Cerrosafe castings and he offers this smart advice:
1. Remove the barrel from the action to make the pour much easier. If you don’t remove the barrel, it can be hard to pour through the action (even with a funnel) and can make a mess if you’re not careful.
2. Pre-heat the barrel for 5-10 minutes in the oven on the very lowest setting (170° F in my oven). (DON’T overdo it!). Allow to cool for a couple minutes so you can pick it up and it is under 120° F. Pre-heating the barrel helps the Cerrosafe stay liquid as you pour the casting. This helps ensure a good, complete fit to the chamber.
How to Use Cerrosafe for Chamber Casting
The basic ingredient of Cerrosafe is bismuth. Bismuth is a heavy, coarse, crystalline metal which expands when it solidifies, up to 3.3% of its volume. When bismuth is alloyed with other metals, such as lead, tin, cadmium and indium, this expansion is modified according to the relative percentages of bismuth and other components present. As a general rule, bismuth alloys of approximately 50% bismuth exhibit little change of volume during solidification. Alloys containing more than this tend to expand during solidification and those containing less tend to shrink during solidification.
What all this means for the gunsmith is that you can make chamber castings using only Cerrosafe and a few, simple hand tools. To make a chamber casting, first clean and degrease the chamber. Use a tight-fitting, cotton patch that’s wrapped around a bore mop or brush to plug the bore just ahead of the throat. I usually leave the cleaning rod attached to the plug until it’s time to remove the plug. Melt the entire bar of Cerrosafe in a heatproof container that you can easily pour the hot Cerrosafe out of. You can use a propane torch or heat over a hot plate or the burner of a stove. Cerrosafe melts easily at 158°-195° F. While the casting metal is still liquid, stir very well, skim off the dross, and pour your chamber. The real trick with Cerrosafe is not to overheat it. If you heat the solid slowly, and keep it within the required temperature range, you shouldn’t get any dross.
Note the time the casting was poured. The casting will take only a very short time to solidify, usually within a minute. Wait 30 minutes and then remove the plug from the bore. Turn the muzzle upward and the casting will fall from the chamber. At 30 minutes after initial solidification, Cerrosafe shrinks slightly, so removal is very easy. Allow the new casting to cool thoroughly then measure the casting exactly one hour from the time it was cast. The casting will give you an exact measurement of the chamber. Cerrosafe casting metal can be used over and over. Remelt the entire amount back together and pour the Cerrosafe into a small mold of the appropriate size. Always melt the entire Cerrosafe ingot to make a chamber casting. For best results, never cut off, or use, just a part of the ingot.
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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.
That said, 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 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 $16.99 each from Sinclair International.
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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.
That said, 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 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 $16.99 each from Sinclair International.
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Are you a crack shot and want to be a Hollywood Star? Pilgrim Films (producers of American Chopper, Dirty Jobs, Ghost Hunters, and The Ultimate Fighter) is casting a new television show about marksmanship for the History Channel. If you are skilled with a pistol, rifle or any other firearm, you could win $100,000 in prizes on Top Shot, a new marksmanship competition TV show. The History Channel is looking for anyone with “mind-blowing shooting skills and a big personality” for the new show. According to the producers, “As long as you’re in good physical shape, have mastered a firearm and can adapt to new weapons and demanding physical situations, you could be America’s first ‘Top Shot’.”
To apply, email TopShotCasting@gmail.com with your name, city/state, phone number, a recent photo of yourself and a brief explanation of why you are America’s “Top Shot”. For more info, call 818-728-3729. Deadline to apply is January 18, 2010.
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Cerrosafe is a metal alloy that has some unique properties which make it ideal for chamber casting. First, it has a relatively low melting point of 158 to 190° Fahrenheit. This makes it easy for the handloader to melt the Cerrosafe in his home shop. Second, it shrinks slightly during cooling which allows it to be extracted from the chamber easily. It then re-expands to the chamber’s original size after about one hour at room temperature. After cooling for about 200 hours, the chamber cast will expand to about .0025″ larger than the actual chamber size.
Wolfe Publishing offers a companion DVD, 
