Sanford and Son Casting

Stonecrusher

Active Member
I just upgraded my Noe 246105FN 2-cavity aluminum mold to a 4-cavity brass. Only my second big brass mold and it is heavy! Bought it to speed up casting and was going to make it work with my bottom pour furnace. Tried dipping first and it wore my wrist out, but sure makes great bullets!

The "Mold Guide" on the 20lb Lee just doesn't cut it for me. So I made a nice shelf with adjustable guides on it, and it sure takes the weight off the wrists... Then I got lazy!

I cobbled together a foot control so I could use both hands on the handles and didn't have to hold my right arm up in the air for hours on end.

I pop riveted an piece of 1" aluminum angle with an 11/16" hole drilled in it onto the pot's handle strap below the knob so it is still usable that way. The push rod is a piece of steel tubing that used to be my neighbor's glider chair. He threw it out and I thought I might have a use for some scrap metal. The foot pedal is a hinge off my old garage door that I replaced and has another piece of the glider bolted to it. A cotter pin and a washer made from a piece of heater hose(just to keep it from making a tapping racket) complete the job.

Pictures are below. Don't laugh! I know it is ugly but it is hidden in the garage. The beauty is in the function. You wouldn't believe how much less effort it is to cast using a foot pedal! Takes at least two thirds of the work out of it just by not having to trip the lead flow with a raised hand. I could hardly make myself stop the first time I used it. I cast about 350 of the 246105's then about the same number of Lee 311-93 1R for the 30-30, and still hadn't had enough. So I dug out my 2-cavity 358477 and ran about half of a large coffee can of those. Hadn't used that one in a while as I have been on a wadcutter kick. Those 2-cavity molds do go a bit slower but that mold sure runs great. The wife finally made me quit!

Only thing I have changed is to add a riser to rest my foot on. The pedal sits a couple of inches off the floor and my ankle gets tired having to hold it at an angle. The riser keeps my foot flat and makes it much better.

Foot Control 1.JPG Foot Control 2.JPG
 

Ian

Notorious member
That's outstanding! You won't hear me laughing. I do wonder though, how you have a Lee pot old enough to have a wooden knob and it still looks brand new. Mine looks like it has been through three wars and was recovered from the bottom of the Atlantic. I think I've run somewhere around two tons of lead through it.
 

Stonecrusher

Active Member
That's outstanding! You won't hear me laughing. I do wonder though, how you have a Lee pot old enough to have a wooden knob and it still looks brand new. Mine looks like it has been through three wars and was recovered from the bottom of the Atlantic. I think I've run somewhere around two tons of lead through it.
Well, I did clean it up a bit when I had it apart to put the shelf on, but then again it hasn't had two tons of lead thru it, probably a little less than 1/2 ton. I think I have only had it about four years. The old Mag-20 next to it i have had about thirty years.

Thanks for the compliment!
 

Brad

Benevolent Overlord and site owner
Staff member
Brass moulds are nice but very heavy. A 2 cav isn't bad, 3 is managable, but a 4 cav is a real bear. I have a couple and while I use the heck out of them they do wear me out.
 

Stonecrusher

Active Member
Brass is heavy, but works almost as well as iron for me. I was having problems getting the aluminum 2-cavity to work to my satisfaction when bottom pouring. The brass is working well. Checked after culling and after weighing about a third of the 246205's, they were all within .7grn, so I quit. The old 2-cavity had two distinct weights .5 grn apart so the brass is more consistent with twice the cavities. If they shoot as well without weight seperating, which they should, I have sped up the process.
 
F

freebullet

Guest
So when is the lee 20 to automated master caster like conversion mod going to be ready for shipping? Cuz I'm in!

I'll probably need 2 to keep up with the ar9.
 

Stonecrusher

Active Member
So when is the lee 20 to automated master caster like conversion mod going to be ready for shipping? Cuz I'm in!

I'll probably need 2 to keep up with the ar9.
Hadn't thought about selling them. Would need some refinement, and that was my only garage door hinge!:rolleyes:
 

Ian

Notorious member
So when is the lee 20 to automated master caster like conversion mod going to be ready for shipping? Cuz I'm in!

I'll probably need 2 to keep up with the ar9.

You need the dual spout version with a heated, dual mould guide and a pair of 4-20s mounted overhead to feed pre-melted ingots to the casting pot. And an ingot conveyor rigged to a gear motor. And a helper.
 
F

freebullet

Guest
You need the dual spout version with a heated, dual mould guide and a pair of 4-20s mounted overhead to feed pre-melted ingots to the casting pot. And an ingot conveyor rigged to a gear motor. And a helper.

Well of course, I thought he was working on the rest of the system now.:D

That would be the ticket if a guy could automate with Lee 6 cavs on the cheap. Literally tons of bullets.
 

KHornet

Well-Known Member
Am amazed at some of the things that the members of this forum
come up with. Would make some of the old time casters green
with envy!
 

358156 hp

At large, whereabouts unknown.
I've noticed that a lot of the basement engineers here would be working for NASA except they didn't want to get "dumbed down" by an engineering degree. FWIW, my oldest brother retired as a mechanical engineer for NASA. To this day, his thought processes start with a piece of paper and a formula. Me? My thought processes start with "what do I want?", and "what do I have to make it from". Most casters seem to fall into the same category I do. I think most of the worlds greatest inventions started with a daydream. Err... I mean a vision.
 

JWFilips

Well-Known Member
Those are really slick mods for the Lee pot! I'm always fighting with the mould rest. One of these days;)
 

Todd M

Craftsman of metals...always learning.
I love the foot pedal! I'll have to do that for my old Lee 10 lb'er.
 

Brother_Love

Well-Known Member
You can get garage door hinges at Lowe's, I have one hanging in my shop. Thank you for showing me what to do with it. I will start on my "foot pedal" control Monday. Thanks for the idea and pictures.

How about a few more instructional photos?

Thanks, Malcolm