Mountain West
Malachite’s Big Hole
Mountain Men and Life in the Rocky
How to Make Small Lead Bars:
Small lead bars weighing approximately one-pound, were a common item taken to rendezvous in the mountains. St. Louis prices for small bars in the 1830's was about 7¢ each. At one-pound, these lead bars were convenient to handle and to recast into balls.
To cast small lead bars, first make the mold. I route channels into a wooden board. I've used both plywood and hardwood. Molten lead does char the wood,
and hardwood will last longer than softwoods or plywood. I make the channels eleven inches long. I start off by routing a flat bottom, 7/32" deep with a half inch diameter flat bottomed bit. I then flare the sides using a 3/4" diameter round bit set to a depth not quite 7/32" deep. As long as you've got your router set
up, go ahead and make multiple channels. It doesn't take much more time, and you'll be able to cast a lot more bars before you need to make another mold. Lead bars with these dimensions will weight approximately one and one-half pounds.
Lead can easily be melted on an electric or gas stove. If you're married and stove-top metallurgy is not an option for you, a white gas camp stove in the basement or garage will also work. Molten lead does give off fumes and it is highly advisable to do your casting in a well ventilated area or out of doors. When handling molten lead you'll also want to be extremely cautious, as it will cause third degree burns in an instant. When pouring the molten lead, there is no hurry, the lead will not start solidifying for several minutes after its been removed from the heat. Fill the channel until the meniscus is slightly higher than the channel. At this time I spritz it with water; it helps solidify the lead faster, and minimizes charring of the wood mold. After the lead bars are solid (don't rush it to much or the bars will tear coming out of the mold) turn the mold upside down and rap the bottom with a hammer. The bars will fall out of the mold. Don't be in too much of a hurry to pick up your new toys, they will remain scorching hot for several minutes.
You want bar lead but can't make your own. Click here to purchase lead bars.
Lead can easily be melted on an electric or gas stove. If you're married and stove-top metallurgy is not an option for you, a white gas camp stove in the basement or garage will also work. Molten lead does give off fumes and it is highly advisable to do your casting in a well ventilated area or out of doors. When handling molten lead you'll also want to be extremely cautious, as it will cause third degree burns in an instant. When pouring the molten lead, there is no hurry, the lead will not start solidifying for several minutes after its been removed from the heat. Fill the channel until the meniscus is slightly higher than the channel. At this time I spritz it with water; it helps solidify the lead faster, and minimizes charring of the wood mold. After the lead bars are solid (don't rush it to much or the bars will tear coming out of the mold) turn the mold upside down and rap the bottom with a hammer. The bars will fall out of the mold. Don't be in too much of a hurry to pick up your new toys, they will remain scorching hot for several minutes.
You want bar lead but can't make your own. Click here to purchase lead bars.