Charlie’s the man on shooting pumpkin balls; I’m just trying to catch up and shoot my first one. After I cast a few with the new mold, I'm going to measure the diameter from a bunch of different angles, because the balls definitely aren't perfectly round. From what I can gather from the source website, Charlie's mold was made on a lathe with a ball fixture, so it's probably a lot more precise than the ones from the supplier mentioned earlier (TOTW). I'll use the sawed-off coach gun and first roll the balls down the barrel to make sure they pass through without issues. Chokes matter: when they were first offered, barrels with chokes were often marked "NOT FOR BALL”; something to take seriously.
It is my understanding that the pressure of a given load is influenced by the composition of the projectile as well as its weight. In other words, it has been said that a given weight of very large buckshot creates more pressure than the equivalent weight in smaller shot, all else being equal. Perhaps the experts on the forum can confirm or dispel this notion. If true, this is something to consider if your barrel wall thickness or condition is marginal, and when deciding on a powder charge. Guns ordered explicitly for shooting pumpkin balls would most likely have been configured with larger frames and heavier barrels, more like a musket.
Lead fumes are not a big deal in a ventilated area unless you get the lead too hot (approaching or exceeding 1000F). You shouldn't need to go above 750F or so; another reason to use a thermometer. Perhaps more important is washing your hands frequently while handling lead (avoid eating while casting), and of course safety glasses/goggles. Don't cast barefoot or with open-toed footware... I speak from experience!
Be safe and have fun!
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