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Lead Processing
Posted: Sat Jul 08, 2017 11:30 pm
by Andrew Robinson
Re: Lead Processing
Posted: Mon Jul 10, 2017 6:33 pm
by Andrew Robinson
Re: Lead Processing
Posted: Tue Jul 11, 2017 2:33 am
by Richard Hull
As a bullet caster and low melting alloy producer, I have worked with lead, cadmium, tin, zinc, and antimony a good bit. It is definitely an outside effort when melting and casting any of these heavy metals. I am glad to hear you did the right thing especially when working with such large surface areas in the melt and cast. After many years at it, I drool continuously in small amounts and the tremors are bearable. I forget a lot, too. (just kiding)
Richard Hull
Re: Lead Processing
Posted: Tue Jul 11, 2017 5:21 am
by Rex Allers
Andrew,
Interesting HEAVY project you are undertaking. Looks like eventual completion is a lead brick cinch. What are you using to melt all this stuff? Is it a home-brew furnace or something commercial? Gas fired?
I wouldn't mind getting some clean lead but being on the west coast, I think I'll just watch from afar. I have received a couple test proofs of "if it fits it ships", but if that could work I'm not sure I would want to punish my local USPS guy at that extreme.
Richard, was that a reference to lead poisoning symptoms? I was trying to think of a clever "mad as a hatter"-type reference but nothing came to me.
Re: Lead Processing
Posted: Tue Jul 11, 2017 1:02 pm
by Andrew Robinson
Hahaha, yup you know me Richard. I always use an abundance of caution in everything I do.
- Mostly for toxins burning off from glue and other nasty stuff, but there was quite a bit of lead dust that was initially stirred up as well. Better to have it and not need it, then need it and not have it.
Rex, currently I use a high volume gas burner with a large (deep) cast iron dutch oven that you can find at most camping suppliers. This gives a large enough volume to fully fill several very large ladles which allows us to cast large objects. We currently use two 6" diameter ladles. This is about as large as you want to go. Anything larger and it becomes so heavy that its difficult to handle and pour. The burner runs off propane. We can get several hours (8+) on a single tank. The melt time is exceptional too with the exception of the beginning of the day when everything is cold. Once up to temp, the process is very quick. As for shipping, yeah that is going to be tough... This stuff is difficult enough as it is just moving it a few feet across the room. I think I will probably stick to dealing locally. Sorry.
- Bayou classic works fantastic! I may look into building my own super burner soon though.
Re: Lead Processing
Posted: Tue Jul 11, 2017 2:35 pm
by Richard Hull
Rex, yes, I was being humourous about the symptoms of heavy metals poisoning.
I, like Andrew, do wear a proper filtered mask to breathe in and around a melt, even outdoors. The vapor pressures of particularly, cadmium, zinc and lead, in that order, are high enough that theycan cause serious long term effects.
I have ordered large amounts of lead in the form of 25 pound sacks of reclaimed shot from Rotometals who offer free shipping of same if the order exceeds $100. A hundred bucks buys a lot of lead! I suppliment my lead orders of 50 lbs with Lyman #2 bullet alloy that Rotometals also kindly mixes up for me or anyone, actually. I used to have to melt into existence this special bullet alloy, but Rotometals now saves me that task.
Rex noted "if it fits it ships".. Silly USP! I got a 50 lb order of shot in a single rather small USP prioity box that was covered with nylon filament tape. The postman would not deliver it to the house as it was too heavy. I took the pink slip to my local post office and they brought it out on a hand truck. The rectangular box had, in shipping, assumed the shape of a small mellon!! Thank goodness for that half roll of filament tape!
I find that lead shielding need not be cast up! A good heavy wooden box of the correct desired dimensions can be filled with the tiny #7 shot which rotometals ships, avoiding the need for melting. Actually, the shot is not graded as it is reclaimed. I asume it is reclaimed from shotgun ranges. The shot ranges from #7 through #9 in size, but is small enough to not allow any significant air space voids between shot pellets in large dimensional thicknesses.
Richard Hull
Re: Lead Processing
Posted: Tue Jul 11, 2017 2:54 pm
by Andrew Robinson
Richard Hull wrote: A good heavy wooden box of the correct desired dimensions can be filled with the tiny #7 shot
Yeah I have done similar solutions in the past. Its a somewhat hackish solution though and there is always the possibility of breaks and spills. Casting custom solid shapes in my opinion is always the best and most professional solution if you have the capability.
I'll have to bookmark Rotometals. Looks fairly reasonable for pre-processed lead.
Re: Lead Processing
Posted: Tue Jul 11, 2017 4:42 pm
by Rex Allers
On USPS packages, I ordered a bunch of Corian counter top cutoff scraps from ebay to use as insulators and whatever. That came in one Priority box and survived only by strong tape. The mail guy delivered the heavy box to my door and asked what was inside.
For lead, I ordered two 50 lb rolls of lead flashing (0.050" thick). That should serve my immediate shielding needs and should not be difficult to wrap around any sturdy form or device. I can't remember if they came by USPS. They may have. I do remember that something resembling a package only remained due to strong tape.