casting bird shot

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I haven't tried it but I have tried popcorn (unpopped) and dried beans, the round seeds tend to come unstuck from the resin and leave little divots all over the blank. I think round bird shot might do the same. Only one way to find out for sure, give it a try.
 
The lead dust is definitely a concern. I thought if the shot were to be glued closely to the tube that it would clear the turning (maybe glue up the tube and roll it in the shot and have it stick in a layer). My other thought was having air trapped in between the balls causing problems. I've not yet tried casting so I'm not talking with any experience, but I'm wiling to give it a whirl. Just thought I would throw the idea out there and see if has been tried and to what success.
 
It might work if you glued the shot in a pattern around the tube perhaps to mimick the pattern as it comes out the barrel and use a shotshell for the top tube. tighter at the top and spread out at the bottom. You will need a felt or cardboard centerband for the wadding.:) I would also recomend a dust mask if not a full face shield and gloves for turning.
 
I've tried using Orange Airsoft balls. That didn't turn out so well. Balls were becoming unset from the blank. Granted this was literally one of my 1st attempts at casting like 4 months ago. I should give it another attempt since I bought some glow in the dark balls to try out. :)
 
I wonder what would happen if you took a wood barrel and spun it down to size. Then put a dowel through the pen to a piece of wood and glue it there, to hold the pen upright and steady. Then get out the smallest birdshot you can find...low power, like a 22 birdshot round. Shoot the pen. Then load another round and go shoot the pen again from 1/3 around..so you shoot the pen 3 times from 1/3 around the pen. The pellets and pattern will be all around the pen and embedded in the wood. You'd need a strong wood, but not a really hard wood...I'm thinking something like a Birch maybe. Then you can CA over all the pellets and assemble your pen. This is all just a theory I came up with on the fly of course. Does it work, I don't know, but it sounds pretty cool in my mind!
 
I'd try find small enough shot to cast under the clear resin so that you wouldn't turn down to it.
Not sure you'd end up with 'dust' if a skew came in contact with lead from a shotshell... The stuff is pretty soft(when compared to other metals), and it isn't what I'd can 'dry' by any means....
I would tend to think it would be more like a 'flake' or something.

Here's a link to show a chart for 'sizing up shot'
Scroll about halfway down...


Scott (like to see when you finish it) B
 
Gonna be a heavy pen, regardless, but copper-clad BBs would look prettier ... :)

As for the trapped air, how about adding the shot to the mixing container before filling the mold?
 
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