Sunday 7 January 2018

The problem of non-expanding lead bullets



Cal Ward on Guns (formerly of The Irish Shooters’ Digest)



The problem of non-expanding lead bullets




This headshot feral ram was taken with a .45 calibre 325 grain Keith bullet with a velocity of around 1200 feet per second – hardly a “soft” load – and while obviously lethal, the wound channel, clearly visible after the head has been prepared, shows little evidence of expansion.




The modern rifle hunter, whether he hopes to kill varmints or large game, goes into the field with equipment including ammunition that represents several hundred years of refinement and development.  He uses a bullet, jacketed or unjacketed that is designed to penetrate and expand on whatever game he is hunting.  His bullet may be a hollowpoint, softpoint, ballistic tip or solid depending on the quarry.  This was not always the case and two hundred years ago a gentleman on “shooting leave” relied on a muzzle-loading firearm that fired either shot or round ball from a smooth bore.  There was a lot of game back then and the guns were often by Mr Purdy or Mr Churchill or Messrs Holland & Holland and were of the finest quality.  There are reports of 200 yard shots on antelope, bear, wolf etc. by officers of the East India Company who ventured into Persia, Afghanistan the Caucuses, Kashmir and Punjab.  They did a spot of espionage while they were at it and reported back to their imperial masters on the state of local defences and the morale of the local military.  They took a particular interest in the Russians who were at that time threatening to invade India.  Their baggage always contained several hundredweight of lead and black powder and gifts, frequently firearms, to sweeten the local bigwigs.  It was an adventurous, exciting and privileged lifestyle and back home in dear old England their memoirs were devoured by Victorian society, politicians and military planners.  Of course it was not without risk and many were murdered, robbed, gang-sodomised or hanged as spies and some would say not nearly enough of them.  They believed unquestioningly in the superiority of Anglo-Saxon civilization and Empire and the Christian faith and never doubted they were doing indigenous peoples a favour by civilizing them even if that process involved massacre, confiscation of land, destruction of culture and livelihood.  They were also brave, young, excellent shots and superb horsemen and their non-homicidal descendants today are the likes of David Attenborough and Ranulph Fiennes who embody all the best and little of the worst traits of the Victorian explorer.




The lethality of unjacketed lead bullets in rifles like the .45-90 Sharps is beyond question.  Modern high velocity expanding hunting bullets are, by the same token, even more lethal


But to return to their favourite hunting ammunition, the round lead ball.  The Baker Rifle of the period fired a .625 lead ball of around 350 grains with a greased patch.  A modern 12 gauge shotgun ball runs from .69” to .73” depending on the degree of choke.  Prior to the formation of an Experimental Rifle Corps in 1800, a trial was held at Woolwich by the British Board of Ordnance on 22 February 1800 in order to select a standard rifle pattern; the rifle designed by Ezekiel Baker was chosen. During the trial, of the twelve shots fired, eleven were placed in a 6-foot circular target at a distance of 300 yards.  Muzzle velocity was variable at around 1,000 fps and the projectile developed around 600-700 foot pounds.  It was an inefficient projectile and decelerated quickly downrange but tended to deliver killing power out of proportion to its energy because it tended to dump all of its energy in the target without exiting.  If the hunter was a skilled stalker who could get to less than 100 yards from his quarry his chances of a kill were as high as those of a modern hunter.  Because of its construction the round ball tended to expand on bone and this added to its lethality.  It punched above its weight as it gave up most of its energy within the target.  A lot of people and animals were killed by round balls of lead two hundred years ago.




After his gun and his horse and of course food, the adventurer of the 19th century needed only some black powder, lead shot and balls, and after 1870, brass cases.  Thus equipped they ranged from the Caspian Sea to the Hindu Kush and throughout India and Africa


Time passed and metallic cartridges replaced percussion muzzleloaders and round balls gave way to elongated lead bullets and by the time of the American Civil War rifles like the Sharps were shooting 500+ grain elongated lead bullets with grease grooves at velocities of up to 1500 feet per second and their effective range exceeded that of the Baker rifle by several hundred yards with a hugely increased rate of fire.  In many ways lead is the ideal bullet material.  Pure lead maintains its uniformity and lack of brittleness (molecular cohesion.  By swaging the lead, the hidden voids and uneven core problems of cast lead cores are removed.  Swaged lead bullets can be more consistent in weight than cast counterparts. Pure lead bullets shorten and belly out upon firing, sealing gases and engaging the rifling.  When they get to the target they retain more energy than lighter projectiles and under the right conditions will deform and expand.  As the old shooters used to say; “lead is dead”.




Bulletsmithing the old-fashioned way over an open fire.  Inset: a modern reproduction Pedersoli brass mould


There is one problem – expansion.  Despite what the experts say, it can be difficult to get a lead bullet to expand.  We have all hunted rabbits with hollow point lead .22 high velocity bullets and these expand nicely on small game.  Problems arise when we switch to subsonics which, because of their lower velocity, do not expand nearly as well.  This is why hunters who use subsonics prefer head shots.  It is the same with .45 lead bullets and it is not at all unusual to see fired .45 heads in the backstop that could easily be re-loaded and fired again without any preparation.  I have done it many times although I have noticed a fall-off in accuracy.  Battered slugs are less accurate.  I have hunted with .45 calibre rifles and have noticed the wounds, while lethal, showed little evidence of expansion.  .45 calibre 500 grain slugs tend to over-penetrate at 1200 feet per second.  A classic case was a large feral ram I killed with a head shot at 50 yards and by an unbelievable stroke of luck found the unexpanded bullet where it had struck mud a few feet behind the animal.  Lead was dead, but….

 A modern electric Lee lead melter and some shiny new .45 cast bullets


So what does it take to expand a lead bullet?  I already knew four things from previous experience: (a) soft lead expands better than hard lead alloy and (b) small calibre hollowpoints expand better than solids and (c) if you push lead fast enough it will expand on impact and (d) larger calibres are less likely to expand than smaller calibres.  What about a large calibre hollowpoint lead bullet?  The idea had been in the back of my head for years and I used the occasion of a bout of ‘flu to set up an experiment.  The flu was a nasty dose and Audrey confined me to barracks (but not to bed) for the duration so I put a half bag of blocks in the workshop stove and went to work.  I decided to cast a bullet that could be fired from either rifle or pistol and selected a classic mould for the .45 calibre Keith 250 grain semi-wadcutter – a versatile head for the .45 1911 Colt semi automatic, the older Colt .45 SAA revolver and a whole tribe of .45 lever guns.  Getting hold of hollowpoint cast bullets for hunting with a large calibre muzzleloader or metallic cartridge rifle is a little more difficult and the hunter-bulletsmith must somehow acquire a hollowpoint mould or purchase factory cast bullets from a dealer or drill out solid bullets to make them hollow.  This last operation is difficult because, while drilling lead is easy; drilling out exactly the same amount of the stuff every time without making a tubular fishing weight is harder and precise removal of that last few grains is downright tricky.  The first and most interesting lesson was that standard cast solids they didn’t do much when fired from a Colt Peacemaker using a full load of 23 grains of black powder.  They came out of the sand rougher, brighter, cleaner with impressive rifling marks and no distortion or expansion whatsoever.  I felt like writing to Clint Eastwood about it to question some of those badguy kills he made with Lee van Cleef and Eli Wallach but thought better of it.  He probably used purer lead and had better black powder or maybe the badguys were tougher and expanded his bullets better.  The same bullet fared little better when fired from a hunting rifle at medium velocities of 900-1100 feet per second.  At 1300 fps things changed and some spectacularly flattened slugs were retrieved from the backstop.  Hunting hollow points at medium velocities, when retrieved were found to be stuffed with wood fibre and sand and disappointingly unexpanded.  Obviously 700 – 1,000 fps was insufficient velocity to expand a lead hollowpoint.  1,300 fps produced a nicely expanded bullet, however.  Accuracy at 25 yards with hollow points was acceptable if not spectacular.







On the left an expanded hollowpoint 250 grain hunting bullet fired at 1.300 feet per second and in the centre, the same bullet fired at 900 feet per second.  The vintage photo of an expanded lead ball on the right is by way of comparison. Lead will expand but only if driven sufficiently fast.  The difference in expansion between hollow and solid point bullets at lower velocities was not obvious.



The trial raises interesting questions.  At the time of its adoption the .45 Colt Peacemaker or Single Action Army was put through trials by the US Government.  One requirement, it has been reported, was that a cavalry revolver should be capable of killing a horse at 25 yards.  Even allowing for the fact that early Colt .45 cases had thinner walls and a larger capacity of 40 grains of high quality black powder as opposed to my 23 grains of Russian (poor) substitute, the performance falls short of horse lethality.  But then if the unfortunate beasts killed in trials were shot in the ear, perhaps they died quickly.  I’ve often wondered how the US Army organised horses to test the lethality of bullets.  Did they shoot only sick or old ones?  Military trials, then as now, were often accompanied by lavish “hospitality” and judgements were thereby influenced.  Whatever the truth of it, a lot of people have put their faith in this bullet in both rifle and pistol for over 150 years.  


Happy is the hunter….  A frequently overlooked fact is that the Muzzleloader rifle of the seventeenth and eighteenth century, while inefficient compared to modern firearms WAS powerful and provided it was of sufficiently robust construction could handle large loads of 150+ grains of black powder and large bullets of 500+ grains capable of taking the largest game



And what of the ethics of hunting with large calibre cast bullets, both expanding and non-expanding?  As I see it, the only difference is range.  A round ball or large calibre elongated bullet will kill cleanly and a modern small-calibre high velocity expanding hunting bullet will do the same thing at greater range.  It is worth remembering that hunting with 12 gauge shotgun balls and slugs is mandatory in some areas where deer populations are high in areas close to population centres.  That the same projectile is considered inhumane and dangerous in other areas is somewhat hypocritical and shows what happens when the ballistically ignorant become legislators



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