How about using a plaster mold to cast lead projectiles? You could take any size ball you want. My brother-in-law did some bronze castings in collage. He said to use a cardboard milk container and fill it about half way with plaster and set some golf balls (or any other size ball) sticking about half way out. The balls should be coated with transmission fluid so they release. Once the plaster hardens coat the top surface with more transmission fluid and pore more plaster on top. When the mold dries the milk container can be peeled off and the mold can be separated. He warred that the plaster needs to be very dry. It should be baked in the oven for several hours just before you cast. The mold can then be reassembled and pored.
It seams like it would be a relatively easy way of getting any size projectile you want. It would be a one time use mold but it would be cheep and easy to make. You could cast as many projectiles as you could melt lead for.
Any ideas?
