Shotgun Tech: How to turn Birdshot into slugs

Posted: April 11, 2012 in Weapons
Tags: ,

I thought this was a very interesting and informational post.  Not be discussed in depth at this time, but buckshot and slugs have different applications. Overall buckshot is cheaper so more often than not people have that on hand for defense, or bird and rabbit hunting.  Steel shot cant be used in this manner, but lead can.




This post was on The Firearm Blog, the writer was “Y Man”


Imagine that all you could ever get in terms of ammunition is this:

Ordinary 12 gauge, BB Birdshot.

Well, I got some of that, but was I satisfied? NO! I needed something I could really use to “Reach out and touch…” Something that would penetrate at range with some accuracy.
I got a mold fabricated: 25.3mm thick Steel, drilled through at 16.5mm wide, and drilled right through to the other side.

A nut was welded to the bottom carefully to take a 10mm bolt that would serve to create a hollow on the planned slugs.

I opened up a 12 gauge BB shell using a basic knife to remove the lead shot.

Using modified sharp-nose plies I removed the plastic cover of the Shell.

The lead shot is poured out and cleaned, and the plastic bits removed…

A felt wad is pushed into the empty shot-shell, seated very well into the shot-cup. The diameter of the wad is same with the Shot-Shell.

The Lead Shot is poured into a Ladle, and melted. Working with Lead is VERY hazardous: ensure eyes are protected, use safety gloves, ventilate properly!

The Mold is carefully placed on a good flat surface.

Molten Lead is carefully poured into the mold.

The Bolt at the bottom is unscrewed carefully. NO wiggling it around!

Use a pointed item to push the cooled slug out…

You may have to knock it a bit to get it out…

This is the produced Slug…

This is the produced Slug…

More pictures of the finished slugs. Nice factory-like finish…

Next: Insert the Slug into Shell case…

Some force is needed to get the Slug into the Shell-case. This is due to the Roll-crimp which was not touched originally…

You can see the Slug inside the Shell-case, centrally placed, snug against the crimp…

LAST STEP: Glue or epoxy is used to seal and waterproof the Shell-case properly. Left standing upright to dry/ cure.

Glue or epoxy is used to seal and waterproof the Shell-case properly. Left standing upright to dry/ cure.

Slug is ready to be FIRED!

I test-fired a few slugs today (16 August 2009)! Perfect performance (for what i had at hand…).

5 slugs fired at 30 metres (33 yards, 98.4 ft). Target was piece of metal plate about 1.5ft x 1ft, 2mm thick. 3” x 3” bullseye painted on.

Target taken at 30 meters distance.

Distance Fired: 33 yards
Sights: Bead sight
Ammunition: 5 home-made slugs

5 shots on target. Not bad!
1 round high/ left
4 rounds in/ near the bullseye.

This looks like a 2” to 3” group at 33 yards!

I couldn’t wish for better from home-made foster slugs!






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