.40 Brass backwards in 44 Mag Brass

[bluetopper]

I have an idea for a 44 hollow-base "type" wadcutter bullet. Fill spent .40 caliber pistol brass with 180, 200, 240gr or however much you want, doesn't matter, of molten cast lead and load the open end in a 44 magnum case. When fired the rear of the brass that is not filled with lead has to expand and fit the bore making a very efficient gas seal. The OD of 40 brass is about .425" so it's not going to have to expand much at all to fit the .429" bore of a 44 .
Only problem I see is filling each .40 brass with the exact same amount of lead making consistent projectiles....maybe some can help on this?

And of course we'll have to see what accuracy would be?

For a person such as me who has a 5 gallon bucket full of 40 brass without a 40 caliber pistol, why not try it?

 

[plmitch]

People have been swaging brass cases/lead for years to make bullets. Try it and report back here.

 

[FROGO207]

Reloader Fred does this with 40 CAL brass and has the how to for you if you search. You have to anneal the cases first. Then he makes them into hollow points IIRC. But you probably could do as you say as well.

 

[JT-AR-MG42]

As far as a method for filling them with lead.
Lead shot poured into the case on an electronic scale would be the fastest to obtain your initial goal.

Cheaper way would be to subtract case weight and get a .38 bullet mold that would give you the weight in .44 you want (or close).

Either way, you could put the prepared loaded -with lead- cases mouth up in an old cast iron skillet over a gas flame -turkey fryer burner - to melt the lead in the cases.
Shut down the gas and let them cool when done.
I would do that outdoors for possible vaporized lead from over-heating.
Same method with a propane torch, only slower production.

Either method will also give you the benefit of deadening the elasticity of the brass case.
The case will be very soft when done and could easily have a cannelure rolled on it if wanted.

Or if you just want to fill them with molten lead.
Heat the empty cases to dead soft in the skillet as mentioned above.
Fill the case with the molten lead.
You could then set up a drill press on low speed and drill a slight hollow base in the finished case both to enhance obturation and even out the weight.

Post back with some results, JT

 

[plmitch]

Get a core mold of the correct dia. needed and cast cores, a good set of CH swaging dies and a heavy press and have at it. Thats the easy way. Less headaches.

 

[Elkins45]

Here's an interesting thread on turning 40 cases into 44 bullet with a minimum of equipment: http://castboolits.gunloads.com/showthread.php?144113-My-44s-from-40-S-amp-W

The easiest way to make uniform cores would be just to cast them with a 40 caliber mold.