Black Powder Substitutes for Dummies,

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Light Loads continued:
3. Filler (in this case, Black Dawge Filler*).
Using filler in a Dillon XL650 using 2 powder measures

Using Black Dawge Filler and loading efficiently requires a few changes to your XL650:

Station 1, no change

Station 2, no change

Station 3, replace powder check die with RCBS Lock-Out die

Station 4, another Dillon powder measure. Since there's no way to hook up another safety rod, I just used rubber bands to make sure it closed each time. If you can find one of the springs that came on the powder measure originally, that will work.

Station 5, Lee Seating/crimping die. This die isn't as forgiving of an over-belled case mouth. Adjust die #2 to just flare the case mouth a bit, just enough to get the bullet in reliably.

Black Dawge Filler between 1/8" and 1/16" from top of case
Here, shown large for detail, you can see the Black Dawge filler is between 1/16" and 1/8" from the top. When the bullet is seated, the filler will compress more than the powder. There will be no danger of mixing filler and powder because of the compression, and the round will be very consistent.
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Now the cases have been advanced, and a bullet needs to be put into the case at station 5. If you've been using a XL650 for several years, you'll probably try to insert it in station 4. You'll get over it.

*Black Dawge Filler is ground corn cob with fines and dust removed. It is very consistent in size and inert. It was developed for Black Dawge Cartridge Co. "Reduced Recoil" loads.

Limits

If you shoot one of the smaller cartridges, .38 Special of one of the .32s, you should not have to do this. A .38 Special filled with APP FFg to the base of the bullet is a very mild shooting load that smokes realistically. Reducing the powder charge on a .38 Special or less is not appropriate except for people with handicaps. Reducing the powder charge on a strongly recoiling .45 to make shooting more comfortable and to make up a little for the superiority of small calibers is reasonable. It costs less than a new set of expensive guns in .38 or .32. Loading .38s with the standard Dillon setup and 15-17 gr. of powder is a snap, and you can make volume production loads easily. If you want them mild, use APP or Pinnacle FFg. If you want them hot, use 777 FFg. APP or Pinnacle FFFg will be a bit hotter than FFg but slightly easier to load.

A .38 Special with 5 grains of 777 and a lot of filler will smoke less, but eliminating smoke is certainly against the spirit of the Black Powder categories. If your rounds don't smoke, you shouldn't shoot them in BP categories. Current rules require that rounds smoke as much or more than a 1 cc./15 gr. black powder load. If you load 15 gr. volume of any of the substitutes they will smoke more than 1 cc./15 gr. Goex Cowboy.

Shotgun Reloading
Until I started shooting Frontier Cartridge class I didn't reload shotguns. I didn't shoot enough shotguns to justify the time and effort. Winchester Featherlights can be had on sale at under $5 a box in case lots. I'll buy several cases when I see the sales. But Ten-X gets about $1 a round for American Pioneer Powder loads. First I bought a Lee Load All and loaded with black powder or Pyrodex. But I'd worn it out in a few months, and it was excruciatingly slow. The capper was a squib load at Range War. I was dipping black powder or Pyrodex, and obviously I failed to one time.
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MEC 9000G

So I bought a MEC 9000G progressive loader. I could easily load 100 or more rounds in an hour. I'm not a fan because of the @#$! primer feed. Primers have to drop down a tube, land upright in a hole, and be transported to the next station when the machine advances. The primer feed mechanism gets out of adjustment enough, depending on a cheap little chain for adjustment, that it's a problem. If no primer gets into the shell, powder does and fouls the whole thing. So you have to watch 3 things for every round, the wad, don't forget it, the hull, don't forget it, and the primer. With practice you'll get the hang of it, but you'll waste powder and hulls till you do. Having compressed air to blow the powder and occasionally shot out of the machine helps.

Wad in place, fresh hull in station 1

Wad in place, fresh hull in station one.

The MEC uses powder bushings. This is a negative. This unit came with three, none of which were okay for black powder. The shot bar was a 1-1/8 oz. I've settled on 1-1/4 oz. and got the appropriate shot bar for it. Adjustable shot bars and powder bushings are available from aftermarket sources, but I had already set up using MEC bars and bushings. One of the larger powder bushings (39A) will throw 50 gr. VOLUME equivalent. American Pioneer Powder weighs less than BP, so 41 gr. by WEIGHT equals 50 gr. by VOLUME. (This works for Pinnacle, too). See below for suggested loads. All will knock down knock downs if you hit them.
You have a lot of things to do at once with a Mec 9000
Handle down, watch for the primer falling into place right side up. If there's no primer in that hull at station 2 (left as we're viewing it, to the right of the primer feed), then we're about to have a mess, because there is now powder in it.

American Pioneer Powder in left, Shot in right

American Pioneer Powder in the left. #7-1/2 shot in the right.

I use red Winchester wads (WAA12R) and AA hulls. The red wads hold 1-1/8 to 1-1/4 oz. nominally. #7 is the largest allowed at several ranges. Shown is #7-1/2 shot. The wad cup is full, and the MEC makes virtually perfect crimps when everything is adjusted just right, a condition that's not easy to attain or maintain. Most plastic wads are not suitable for black powder as they take up too much space in the case. These are just right for 50-65 grain loads.
Empty powder back into original container for the night

Empty the powder back into the original container when you're done for the night and clean up around the loader. I don't leave any hulls in the machine, either, to prevent moisture contamination of the powder in a half-finished round. Spilled powder and shot are vacuumed up.

Other than always emptying the powder when you're through for the night and re-sealing it in its original container, it's pretty much like loading smokeless powder, no special grease wads needed, and FFg meters well enough for a shotgun.

Dillon SL900
Dillon SL900, if not the finest shotgun loading press on the market, it's in the top few
Proof you get what you pay for. The Dillon SL900 costs a little over 2X what the MEC did (counting all those bushings and such), but it's about 10 times better. It came adjusted for AA hulls, and I've never adjusted anything but powder and shot. The standard powder measure will handle about 55 gr. If you like bigger charges, you'll need the magnum rifle powder measure. The primer feed is much better than the troublesome MEC. It's still the weakest point just because it's dealing with 100 primers at a time. If you're going to have a malfunction, that's where it'll be. But they're rare. It won't drop powder or shot if there's no case under it! The hull feeder works flawlessly if you select round, clean, good hulls and don't put in more than it calls for. The shot feeder is much superior. Operation is low effort, and results are high speed if you pay attention. So far I've had a grand total of one phone call to Dillon over it for the usual first session screwup. I really enjoy doing BP shotgun shells now.
Recipes:
APP, Pinnacle 777

50-65 gr. FFg (volume, 42-55 gr. weight, see chart)

Red AA Winchester hulls

Red WAA12R Winchester wad (or Claybuster equivalent)

1-1/8 to 1-1/4 oz. shot, 7-1/2 to 9 to taste.

 

39 gr. FFg (volume, 34 gr. weight FFg)

 

Red AA Winchester hulls

Orange WT12 Winchester wads (or Claybuster equivalent)

1-1/8 oz. 7-1/2 to 9 shot.

1-1/4 oz. if desired.

 

 

I've talked to many top shooters, and these loads are close to what they use. No one is using a lot of powder. A lot of powder will blow a hole in your pattern, and the knockdowns will stay up. Black Dawge uses 65 gr., and that's the highest I know of. Red River Drifter's recipe is 55 gr./1-1/8 oz. except he uses wholly black.

Costs

I did some calculating based on local retail prices (probably obsolete numbers by now due to inflation):
Price Quantity price ea. BOX PRICE Charges/lb. Charge wt. Measure
Primer $24.99 1000 0.02499
Hull $8 100 0.08
Wad $4.59 250 0.01836
Shot $15.97 320 0.04990 320 1.25 Oz.
American Pioneer Powder $15 166.67 0.09 166.67 42 Gr.
New Hulls $0.26 $6.58
Reuse Hulls $0.18 $4.58
Your mileage may vary. Plug in your local prices and charge weights for your cost figures.

Brass Clean up

Spent Brass bottle

BP and BP subs are hard on brass. Corrosion starts upon firing, and the way to stop it is to get the brass into something to prevent corrosion. BP and BP subs are basic, so a mildly acidic solution is suggested, such as vinegar and water. The Clean Shot people used to say 50/50. I've tried that but had just as good luck with 90% water/10% vinegar. I've also managed successfully with 90% water/10% Ballistol, 90% water 10% Commercial Windex with Vinegar. The Vinegar/water solution is the official answer from American Pioneer Powder.

 

I prefer using nickel brass:

1. Your brass now looks different from everyone else's. It's easier to keep foreign brass out of your collection. (A .44-40 round got through all the checks and balances and got loaded with a 200 gr. .452 bullet, but it wouldn't chamber and locked up the gun--at a major match of course. I've learned. Now I try to have new brass for major matches.)

2. There is less danger of corrosion and discoloring if the round doesn't get stuck in water quickly.

Disadvantages:

1. It cost more than plain brass.

2. It's not as readily available.

(Starline nickeled brass, available only from sources other than Starline unless you buy 3 drums at a time, is $15/1000 higher than unplated. Try http://www.blue-star-inc.com/)

3. It also won't last as long, being more brittle. It can split on the first firing, and the brass will peel off.

When I get home I rinse the brass thoroughly in clear water and shake it out on colander to dry. After it's thoroughly dry I tumble it clean just like smokeless. If you're in a hurry (and single) you can put the cookie tin in the oven to dry it out. Then tumble.

I have no evidence that discoloration hurts the brass.

Gun Cleaning:
After much study and experimentation, I have devised the perfect solution for black powder substitute cleaning and have made it available at the nominal charge of $10/liter. It is very economical as it is diluted in water 1 part in 10 of water. Go here to order Captain Baylor's Magic BP Cleaning Elixir.
Alternately, if you don't have that:

If you're at home and have running water handy, try it. If not (like at a match) my guns are cleaned with a glass cleaner without ammonia and preferably with vinegar. I spray the guns down and run a bore snake through them with lubricant of choice sprayed on the last few inches of the bore snake. A cleaning brush and Windex/Vinegar does the frame. Then I wipe them down with lubricant of choice and put them away. Complete disassembly is rare, especially on the pistols. The Marlin needs it more often. I'll remove the bolt if I'm cleaning the Marlin at home and clean from the chamber end. The Winchester '73 replica has a brass carrier that is susceptible to black tarnishing. I will spray it with Windex/Vinegar and lubricant after shooting to minimize this. If it turns black, disassemble the carrier and use brass cleaning items such as Brasso. Zep All Purpose Cleaner, used full strength, will get off black discoloration. Keep it away from the blued parts of your gun. Cowboys and Indians Store make a lightweight carrier out of anodized aluminum that eliminates this problem.

The shotgun is the hardest to clean. Plastic wads will melt and coat the bores after hard usage.

To avoid this I spray lubricant down the barrel before putting the gun away to take home.

Ordinarily that will come off with either a good brush or a Bore Snake run through several times. (Once is usually enough 90% of the time.) I just spray Windex/Vinegar down the bore and run the Bore Snake until it's clean. As an alternative to the Bore Snake, take a half paper towel, saturate it with your cleaning solution, wad it up, and shove it through the barrel using a dowel. Usually once per barrel is enough.

After a hard session when I get home I will literally cork the barrels (turned down wine corks!) and fill them with Windex/water and let them soak while I clean the other guns. This has always resulted in a one-pass cleanup using a Bore Snake.

The rest of the gun is cleaned like the revolvers and rifle. When done I make sure every gun has a nice exterior coat of Break Free CLP before being put away. (I got rust using Ballistol/Water--on the outside, not caused by the powder).

Lubricant:

I've used Ballistol, Break Free CLP, and Rem Oil. American Pioneer Powder, 777 and Pinnacle aren't as finicky as the wholly black. If your lubricant works, continue to use it. If you get fouling, it's either your bullet lube or your lubricant. Switch accordingly.

Talk to 2 different shooters, whether they use wholly black or substitutes, and you will get 2 different cleaning methods. Talk to 10 and you'll get 12. The variations in methods and cleaning supplies and lubricants is staggering. It all seems to work. I don't think the exact method is critical.

Now you, too, can annoy your posse with smoke and noise, fascinate onlookers, and make inane comments about how black powder is more righteous than smokeless. In other words, you can have a lot of fun.

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Captain Baylor's Ranger Camp