Well, CowCavalry, here’s the skinny.
I don’t know any other BP hobbyists so I read a lot and watched a lot of videos online then created my own systems for both rifle and revolver cartridges for my reproduction weapons.
About a year ago, after making one purchase of Minie balls from someone else at about $1.00 each, I realized I could easily save enough to pay for the equipment if I began casting my own bullets. I bought a cheap furnace, used bullet molds and some scrap lead, and began casting. I’ve only cast maybe 250 Minie balls, and while I am still learning, the results so far have been satisfying and a lot of fun.
I later bought a revolver and at first just used round balls and loaded the cylinder from a bench. It was such a hassle that I decided to try my hand at making cartridges. I bought a mold for conical bullets, made my own former from a wood dowel, and after a little experimentation produced what I think is a respectable cartridge. I just used some masking paper that I had already purchased for my rifle cartridges but found that it doesn’t quite burn all the way - there is often a little bit of unburned paper left in the chamber. For my next batch I plan to make my own nitrated paper and see if I get better results.
I’ve attached a pic of some of my work. Y’all don’t be too critical - I didn’t have anything to go by except what I could glean online.
BTW, I made a couple of arsenal packs like the one shown with my own Minie balls but with black sand instead of real powder to show visitors at reenacting events what one might have looked like. This is the only one I have left. I ended up giving away my inert cartridges to enthusiastic youngsters.
I welcome any comments, criticisms, etc.