1. What makes a bullet benchrest quality?

The heart of bullet making is in the dies. Bart Sauter advertises the fact that he "got lucky" and got a good set of dies. He is exactly right. The dies we use are hand-made and no two are alike. It does take a bit of luck to get a die that really sings.

A benchrest quality bullet must have consistent jacket walls to keep the bullet in balance. Variations in jacket wall thickness put the bullet in an imbalance situation similar to a washing machine with too many pairs of jeans on one side. At something around 200,000 RPM, the slightest out of balance situation can cause problems. Good quality jackets, being "outsourced" items, are critical.

Consistent core weight is another factor, but not as critical as some would have you believe. For short range benchrest, bullet total weight variances of 2 or 3 tenths of a grain will not be seen on the target. We normally have control of core weight, but different lots of jackets produce bullet weights that may vary by a half grain or more. I have intentionally shot bullets from 2 different lots, that weighed a half grain apart, into the same group with no notable dispersion.

Given a good set of dies and the skill to use them, the quality of the jacket is the single most important factor in producing benchrest bullets.

2. What equipment is needed to make benchrest quality bullets and where can I get the equipment?

Carbide dies are made to last a lifetime of continuous use. Steel dies are infinitely more affordable and will last the bullet maker that makes bullets for himself nearly forever. Steel dies for commercial use have a limited lifetime.

Niemi Engineering is a good source for carbide dies. Larry Blackmon (Bullet Swaging Supply) offers steel dies and my own personal experience with his dies has been very positive. There are other die makers out there that I don't have personal experience with. Others have had fantastic results with them. Talk to the manufacturers that build the dies and make up your mind from there.

Beyond that, modified presses to accommodate the dies, tumblers to lube the jackets, micrometers, scales, etc. will be necessary. These are available thru the die maker, and in the case of micrometers, scales, etc., check the reloading supply houses.

3. What are the essential techniques for producing benchrest quality bullets?

There is really no magic, smoke & mirrors, or God given talent involved in bullet making. To the contrary, it can be tedious factory work. There is checking and more checking the dimensions of jackets, cores, bullet dimensions, etc. After it is all set, bullet making involves endless handle pulling.

Cleanliness is extremely important in bullet making. Clean the jackets in lacquer thinner or acetone to remove all traces of manufacturing oils and to remove any dust or dirt that may scratch an expensive die. The core must be free of lubricant or it will not adhere to the inside of the jacket, or voids may occur. I use a 5 gallon bucket and a carburetor dip bucket, agitate the contents, and air dry.

Dies are occasionally removed and cleaned with brake cleaner. Be sure to use extra lube on the first few jackets after cleaning to make sure they don't stick in the die.

The amount of lube has a bearing on the final bullet dimensions, so it is of paramount importance.

The "dwell time" or time spent at the pressure end of the press stroke has to be consistent. The "feel" of the press stroke can signal a light or heavy core, or the presence of a folded jacket. This feel becomes ingrained and subtle differences between bullets are readily apparent. I have a certain CD I listen to when making bullets--especially during core seating. I get a rhythm going that makes sensing the differences easy.

By all means, keep records of each lot of bullets...all pertinent dimensions etc., and always check the first few bullets you make when resuming a session at the press.

Consider how to share bullet making with reloading operations. An “L” shaped bench, with the bullet equipment on one side and reloading stuff on the other is reasonable. There will be an overlap at times, so make sure to cover the cores, jackets, presses, etc. when not in use. Spilling powder on your freshly lubed jackets will definitely bring a scowl to your face! A clean reloading area promotes safety, as we all know. It also prevents time consuming re-washing of bullet components.

BA