Hey guys, remember that the mold back in the day were what we call a bag mold today. If you have ever measured balls run from these old molds you will find they are rarely round enough to roll away on a slightly out of level surface.
Actually, I
have measured balls cast in a number of original "bag" moulds, and have the diameter variances and weight ranges as close as my notebook. This information comes from various casting runs of >100 balls, cast over a fire, using plumbers' lead melted and poured from an original "St. Louis Shot"-marked ladle. The "44" mould is the one I used for some test with an original Dickert last fall, the first "32" is one a friend uses with his .53 caliber rifle.
1 2 3 4 144 .005 0.3 2.0 142 .002 0.4 1.1 100 .003 0.3 1.1 74 .004 0.6 1.2 44 .003 0.4 1.9 40 .002 0.5 2.0 38 .003 0.9 1.6 34 .003 0.6 1.1 32 .001 0.5 0.7 32 .006 0.7 1.4 24 .002 0.5 1.8 16 .008 0.8 2.1 11 .005 1.0 1.5
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Explanation of column numbers:
1. number marked on mould (balls per pound)
2. variance (out of round) in .001"
3. weight range (trimmed with knife) in .1 grain
4. weight range (trimmed with knife, then filed round) in .1 grain
Granted, these moulds were all selected for their condition--as close to new as possible--but folks in the past weren't typically using worn-out 150-year-old equipment either. I've got far more data on diameters and weights of balls cast from various modern moulds, and these numbers would fall right in amongst them--not the best, but probably not a significant handicap for hunting or most local competition.
(Note that I got far more-consistent results when trimming sprues with a knife and NOT filing the ball round. Especially with those little ones, it is difficult to do consistently.)
The numbers do tend to open up more when weighing and measuring balls cast in various gang moulds of the period. Balls out-of-round by .010" or more, and weight variances of 10 grains, are not uncommon.
As is typical for me these days, I weighed about 10% of my last run of rifle balls (there were 1,027; I only weighed 100). Weight range was from -.3 grains to +.2 grains, so not too bad. These were from a modern mould, using an electric pot: think "production" rather than "research".