John Flanagan of Sabot Designs, a manufacturer known for his flechette-loaded shotgun shells, pointed out that the usual culprit was solvent in the powder doing what solvents do, reacting with other chemical compounds, in this case the primer, rendering the round a dud. As a contractor making ammunition for the government, Flanagan is well aware of this problem and how to deal with it. Flanagan also helped me get the relevant government documents I’ll reference in this story.

THE SOLVENT ISSUE

To begin with, nitrocellulose powders require a solvent to gelatinize them so that they can be formed into balls, flakes, cylinders, or strips. Single base powders are typically an ether-alcohol colloid of nitrocellulose. Double base powders are made from nitrocellulose and nitroglycerine and use ether, ethyl acetate, or isooctanol, as processing solvents. Much of this solvent is lost in processing. The solvent must remain at the minimum level to keep the propellant from becoming brittle and losing plasticization causing the powder grains to turn to dust which will raise pressure dangerously as the smaller the fuel the faster it burns. Just look at how much faster a pile of wood shavings burns than a big log does. Without a certain amount of solvent, you cannot keep the dimensional stability of the powder grains.

This solvent will also act on primer compounds, rendering them incapable of detonation. Because of this, the mil-spec limit for residual solvent in the dried powder is 0.25 weight-% (0.25% of the powder weight). If this limit is exceeded, the life of the primer will be shortened accordingly. These solvents off-gas from the powder and are what you smell when you open a powder can. Back in the days of the Army Coast Artillery, the powder magazines contained so much ether that many thought it was put there deliberately to somehow preserve the powder when, in reality, it was just massive amounts of off-gassing in a confined area.

STUDIES HAVE BEEN DONE

To give you an idea of how much gas can come out of the powder, here is the results of a U.S. military test. A 75-liter drum was filled with 150 pounds of propellant powder containing residual solvent content of 0.25 weight-% (the mil-spec limit for dried propellant). There were approximately 70 grams of solvent. 12 grams of solvent were in the vapor phase and of these, 7 grams were in the space above the propellant and 5 grams occupied the space between the powder grains. The remaining 158 grams of solvent were trapped in the propellant grains.

The 12 grams in the vapor phase were in the form that can act as a solvent on the primer compound. When you add a solvent to primer compound you interfere with its performance, as you’re breaking down the explosive mixture.

This information came from a several government studies I found including:

• 1951, Great Britain’s Ministry of Defense study, Interior Ballistics authored by F.R.W. Hunt (pages 1-7)
• 1966, Julian S. Hatcher, Hatchers Notebook (pages 353-360)
• 1970, E.R. Lake’s Percussion Primer Design Requirements. (pages 2-5)
• 1994, U.S. Army Research Laboratory LOVA Propellant Aging: Effects of Residual Solvent study (pages 1-2, 6, 11, 13)
• 1980, U.S. Army Armament Research and Development Command study titled A Compilation of Hazard and Test Data for Pyrotechnic Compositions (pages 57, 62, 63.)
• 2019, Joint Ordnance Test Procedure (JOPT)-022 Safety and Suitability for Service Assessment Testing for Small Caliber Ammunition Less Than 20MM (appendix A.1-A.5)

WHY IT HAPPENS

Everyone knows not to store ammo at high temperatures, but few know the real reason why. High temperatures drive the solvent into the vapor phase and the solvent vapor kills the primers.

Nitrocellulose itself deteriorates over time yielding acidic byproducts such as nitric acid which can also attack primers. Some powders contain calcium carbonate to neutralize these acids. To absorb the decomposition products of nitrocellulose and nitroglycerine-based powders and prevent their buildup and catalyzing the decomposition stabilizers are added such as diphenylamine, mineral jelly, carbamite, pictrite, and calcium carbonate. These may also act as cooling agents and gelatinizers. These stabilizers can be a health hazard in large quantities and the military has been doing studies on their effect on artillerymen who encounter massive amounts of smoke and chemical residue when firing their artillery.

The combination of all these solvents, acids, and chemicals reacting together results in a complicated combination of solvent gasses with multiple compounds present to interact with your primers. Even the oxidation of lead bullets can spread to the primer and result in a dead primer.

Among the escaping solvent gasses are ether, ethyl acetate, acetic acid, oxalic acid, nitric acid, carboxlic acid, isocatanol, and isoctanoic acid. Ingredients may vary due to the different chemicals initially present in the powder.

All of this volatile chemical cocktail residing in a cartridge case is injurious to primers and over time, when stored improperly, can turn them into duds. If the powder contains more residual solvent content than the mil-spec previously alluded to then the primer will go bad much faster. This seems to be the case with some of the recent lots of commercial ammo that has quickly gone bad in 10 years or less.

From a manufacturing perspective, it’s clear that too much solvent will kill the primer. J. J. Reich of Federal Ammunition says that this is, indeed, why high heat will cause ammunition to go bad. The heat drives the solvent out of the powder and sets it loose to attack the primer. Reich also pointed out that some of the current powders (not those used by Federal) are so hydroscopic that they will absorb enough water in a normal humidity house for the powder fail to ignite.

Joel Hogdon of Remington Ammunition says his company avoids this issue by storing its powder where ventilation can prevent the buildup of gasses coming off the powder and spoiling it by sticking around. He advised that any powder that is discolored, causing a powder can to bulge, or producing a bad smell, should be discarded. Primers, he said, should not be unboxed and left out to absorb moisture before loading into cartridges.

Interestingly, some bullets are now made of porous, powdered metal that can admit moisture to the powder within the cartridge case. The solution to this is a liquid sealant, says Jonathan Langenfeld, the head of R&D engineering at Remington Ammunition. But some types of modern primers must be able to breathe, so you apply the sealant to one side of the primer on some and both sides on others… as well as the bullet. Vacuum seal-finished ammo is another a surefire way to beat moisture absorption by certain hydroscopic gun powders and primer compounds.

OTHER CAUSES

There is one other compound that can sometimes attack primers. Years ago, I had some lead-bullet 38 S&W ammo go bad while the Winchester Lubaloy-coated bullets of the same vintage all fired. The Montana state chemist at the time, John Buchanan, told me that sometimes lead oxide from old lead bullets can react with primers and kill them.

Another thing to consider is that primers require a fast, hard strike penetrating a minimum of 0.017-inch depth to go off. Seth Swerczek at Hornady Ammunitionpoints out that if improper headspace puts the primer out of reach, or there is a slow lock time as can occur with dirt or with congealed lubricant in cold weather, then the primer may not be indented fast enough to fire. He also said that it was sometimes possible for 1-3 primers out of a million produced to be incomplete, lacking anvil or primer compound and thus incapable of firing, though he stressed this was very rare.

THE SOLUTION

The solution is two-fold, depending on how you get your ammo.

For handloaders, use powder that does not exceed the mil-spec limit for solvent in dried propellant. Then, when making your cartridges, shield the primer from the solvents and acids. This was done in the past by the military as shown in the Army’s production drawings of the .45 ACP and 30-06 ammo. Note the part labeled “Seal, case vent” between the primer and the powder charge. That seal is a ten thousandth of an inch thick celluloid plug. It was installed by inserting a strip of ten thousandth of an inch thick celluloid over the primer pocket before seating the primer. The primer punches out the celluloid plug when it is installed, and it stays in place. Ammo thus sealed does not go bad. This is a very cheap and simple solution that anyone loading ammunition can employ regardless of whether you have a big factory with giant plate loaders turning out millions of rounds or a simple Lyman tong tool for reloading.

Handloaders can source these celluloid strips from Flannigan at Sabot Designs LLC, who I previously mentioned above. Flannigan has agreed to sell these strips to any individual handloader or ammunition manufacturer that wants them. Once in place, the primer is protected from the solvents and acids from the propellant powder, so things always go bang when they are supposed to.

For those buying commercially loaded ammunition, look for fresh ammunition lots and store your ammunition away from heat, humidity, and gun cleaning solvents, as these solvents can also attack and kill primers, especially those solvents with an ammonium base.

In the past people blamed the primers but blaming the primer after chemically attacking it is not right. You must put the blame where it belongs. On the chemicals that neutralized the primer.

The cap bodies were simply small, thimble-shaped cups with a base rim flange that were die-formed out of thin iron, pewter or copper sheet (today’s center fire primer caps are formed out of aluminum). A small amount of pressure-sensitive chemical explosive, called an initiator, was cast inside the cap base. Typical initiators used during that era were mercury fulminate or potassium chlorate, in combination with oxidizers. As a group, these initiating compounds were called fulminating powders or simply, fulminate. Today it is known as the “primer.”

Using this fulminated-base cap design as a crude cartridge meant the firing pin could strike the cap’s bottom outside face at any location to fire the cartridge. Since the cap’s base rim (flange) diameter was already small (6.9mm), with very thin metal across its center, Flobert designed a firing pin strike point to impact along the cap’s base rim where the metal was folded to create the flange. Striking this thicker rim area all but eliminated the likelihood of puncture that could vent combustion gas rearward towards the shooter. Thus, the rimfire cartridge was born. So now you know—it’s called “rimfire ammunition” because the gun’s firing pin strikes and crushes a small notch into the cartridge base’s rim to ignite the primer (fulminate), and that fires the cartridge.

These first Flobert .22 BB cartridges did not contain any propellant powder. The only propellant was the fulminate cast into the internal base of the BB cap. Although crude by today’s ammunition designs, the Flobert cartridge led to the elimination of muzzle loading and cap and ball firearms by combining a percussion cap (that later included a pre-mea-sured powder charge) and a bullet in a single, self-contained, easily loaded, weather-resis-tant cartridge.

Parlor Guns

Flobert made use of his new metallic cartridge ammunition in what he called “parlor guns.” These heavy barreled rifles and pistols, many with ornately engraved metal work and relief carved furniture (stocks and grips), were designed for in-home target shooting. In the mid-19th century it was fashionable for wealthy Europeans to have a dedicated shooting parlor or shooting gallery inside their homes. Flobert’s new ammunition fired by his parlor guns answered that market.

Prior to the 6mm Flobert cartridge, a typical “cartridge” consisted of a premeasured quantity of black powder wrapped together with a ball in a tightly rolled paper cylinder or small cylindrically shaped cloth bag, which also acted as wadding (gas check). This fragile cartridge was either breech-loaded or muzzle-loaded (depending on the firearm’s design) and ignited by a percussion cap that was separately attached to a cap nipple (touch hole). While far faster than muzzle loading individual components (powder, wad, ball), this delicate paper or cloth cartridge was neither weather-resistant, nor utilitarian.

In 1888, the .22 BB Cap that Flobert introduced in 1845 was improved and became the .22 CB (conical bullet) Cap. The .22 CB Cap was loaded with a lead-cast .22 caliber conical bullet instead of a ball. It also became slightly more powerful than its predecessor when a few grains of black powder were added inside the percussion cap cavity to boost bullet velocity from the BB’s 400ft/sec to CB’s 700ft/sec. Even so, both the BB and CB cartridges (still available today) are called 6mm Flobert and for all practical purposes are considered the same cartridge.

Unique to that point in history, Flobert designed a distinctive bullet shape for his cartridge using what is known as a “heeled” bullet design. This was necessary because the bullet and the cartridge case outside diameter are the same. Therefore, Flobert narrowed the bullet’s base to form a “heel” or “shoe-like” shape so it could be inserted into the cartridge case.

The Short and Long of It

Thus, rimfire ammunition got its start and continued to evolve. In 1857, Smith & Wesson developed the 22 Short for specific chambering in their newest revolver. The 22 Short used a lengthened CB rimfire cartridge case loaded with 4 grains of black powder that propelled a 29-grain, lead cast conical “heeled” bullet. This success in popularity and performance led to the 1871 debut of the 22 Long.

The 22 Long used the same 29-grain bullet as the 22 Short, but it employed a longer cartridge case that provided the needed space for 5 grains of black powder, which increased bullet velocity to near sonic speed. This was followed by the 22 Extra Long in 1880, which was designed primarily for use in bolt-action rifles. With a case longer than the 22 Long and a heavier 40-grain outside lubricated conical lead bullet, the Extra Long was loaded with 6 grains of black powder.

Building upon these many successes, the 22 Rimfire continued to morph. In 1887, U.S. arms manufacturer, J. Stevens Arms & Tool Company introduced today’s favorite 22 Long Rifle cartridge (22LR). Stevens brilliantly combined the casing of the 22 Long with the 40-grain bullet of the 22 Extra Long and loaded it with smokeless powder. This component marriage gave the 22LR a longer overall length, a higher muzzle velocity and superior performance for small game hunting, plinking and competition shooting. These enhancements also improved 22LR performance and popularity to the point its success doomed both the 22 Long and 22 Extra Long cartridges to obscurity.

22WRF Ammunition

In 1890, Winchester introduced its M1890 slide rifle (pump action) that fired Win-chester’s latest .22 rimfire ammunition improvement: the .22 Winchester Rimfire or 22WRF. This ammunition employed a slightly larger diameter cartridge case than the 22LR and a flat-base, flat-nose bullet, making it ideal for use in pump rifles with tubular magazines. The 22 WRF bullet also differed from its .22 rimfire predecessors’ outside-lubricated grooved bullets (used in the 22 Short, Long, LR and Extra Long) by using inside-lubricated bullets which protected the lubrication from dirt contamination. While demonstrably less accurate than the 22LR, it possessed a notable improvement in killing power.

But the 22 WRF met with obsolescence just prior to WWII as smokeless rifle propel-lants improved so significantly they replaced black powder and nitro-cellulose propellants. By loading this new, high-velocity, smokeless propellant in the 22 LR cartridge, its bullet velocity soared into the 1,300 to 1,500ft/sec range, trumping the 22WRF with increased power at a far cheaper cost per round.

From 22WRF to 22WMR

Winchester debuted the next major improvement in .22 rimfire ammunition in 1959 with their 22 Winchester Magnum Rifle ammunition or 22WMR. The WMR cartridge case is essentially a lengthened version of the older WRF cartridge case with a jacketed bullet. The WMR is offered in a range of 30- to 40-grain unlubricated jacketed (or plated) bullets. While comparable in bullet weight to the 22 Long Rifle, the WMR rounds fly faster, flatter and farther and carry far superior kinetic energy at all ranges. For example, WMR bullet velocities using a 30-grain bullet can easily exceed 2,300ft/sec and 1,875ft/sec using a heavier 40-grain bullet when fired from a rifle.

Because of the WMR’s larger case diameter and greater length, a 22WMR round will not chamber in a firearm chambered for any other .22 cartridge. However, the reverse is possible, and if fired, the resulting hot high-pressure gas venting around the smaller .22 cartridge case can be very dangerous to the shooter’s face and eyes.

Remarkably, in terms of ammunition quantity sold over the last 150 years, 22 Long Rifle far exceeds the popularity of any other commonly used ammunition on planet Earth. Some of the reasons are its low recoil, low cost (per round) and the large variety of rifles and handguns chambered to fire it. However, 22 LR ammunition has experienced sporadic availability issues over the past, resulting from the government’s tightening of firearms purchase and ownership regulations.
Those who experienced the threatening on again/off again times of firearms regulation—especially leading up to the 2006 through 2016 House, Senate and Presidential elections—may recall those times when store ammunition shelves were sold out, and ammunition hoarding became the norm. Today, .22 rim-fire ammunition is abundantly available, but that availability will again become threatened depending upon which political party is in power. Therefore, we should anticipate future ammunition shortages, at which time the political power changes hands. During such times, dating back to the early 1900s, reloading centerfire ammunition has always been a fallback to traverse ever-restrictive firearms and ammunition regulations. But today, reloading .22 rimfire brass has mostly been discounted as the impossible dream.

Sharp Shooter Ammunition LLC

Thanks to Brian Nixon, founder of Sharp Shooter Ammunition LLC, the .22 rimfire reloading story continues; and there is light at the end of the .22 rimfire reloading tunnel (and it’s not the approaching train). Not only is reloading .22 rimfire brass possible (including .22 WMR brass), it’s an easy process if you have the right stuff. Even better, the reloading equipment and components necessary are readily available and affordable should you desire to have the capability available when needed.

Everything needed to get started is available in kit form on the web at 22lrreloader.com/store. Sharp Shooter Ammunition LLC offers two .22 reloading kits, one for 22LR and one for 22WMR. Since LR and WMR use different outside diameter and length cartridge cases, you’ll need to buy the appropriate reloading kit depending upon what you intend to reload.

Sharp Shooter’s reloading kit provides the basic tools necessary to cast your own bullets and reload your spent .22 rimfire brass. Above all, Sharp Shooter has included a detailed instruction pamphlet. Written in plain English and laid out with descriptive close-up photos showing detailed cutaway views, this pamphlet contains everything you need to know to reload .22 rimfire ammunition using the Sharp Shooter kit.

A small, wire dual-purpose scraper/tamper tool is provided as part of the kit. This ingenuous tool serves as a scraper to remove the burnt priming compound residue from the case’s internal rim. The tamper end is designed to help work fresh (moistened) priming compound (fulminate) back into the cleaned cartridge case rim. The priming compound is moistened to make it insensitive to pressure and friction (more on that in a moment).

Manufacturers of .22 rimfire ammunition stuff a small quantity of priming compound into this petite space inside the cartridge case rim. It is this primer material that explodes and ignites the powder charge when the gun’s firing pin strikes the very edge of the case rim. The shot consumes all of the priming compound, and the firing pin strike leaves a characteristic compression dent in the base of the cartridge case rim.

Sharp Shooter additionally offers prim-ing compound ingredients consisting of four small bags of powders identified as, “L,” “L2” and two bags marked “S.” These powders are proportionally mixed per the guidance provided in the instruction manual using the kit’s measuring scoop. Once mixed, the light-gray-colored priming compound becomes pressure sensitive and must be respected in its handling. As a matter of safety, the primer compound should be desensitized by moistening before attempting to work it into the case’s internal rim. Desensitizing can be easily accomplished by using the kit-provided eyedropper to add a drop of acetone, denatured alcohol (even vodka will work) to the primer once it’s loaded into the case. Working moistened primer into the empty rim area is far safer and easier than using dry pressure sensitive primer. The down side of moistening the primer is that it must be completely dried out (at least overnight) before continuing the loading process. That said, the added margin of safety is worth the wait.

Using Sharp Shooter’s priming compound is both easy and reliable, but other priming compound, like Prime-All, is available from commercial sources. There are some priming compound homemade alternatives that can be realized by harvesting the powder contained in commonly available things, like strike anywhere match heads or the contents of party poppers you throw on the floor and pop when stepped on. Even powder contained in toy gun cup-type roll caps can be gently scraped off and collected for use as a primer. In all cases the primer should be moistened for loading safety.

As a side note, the question always seems to arise as to whether a reloaded rimfire round will reliably fire if the firing pin hits the same indent left from a previous firing. The answer is somewhat dubious. First, the firing pin dent can be knocked back out by using a small pin punch or flat blade screwdriver, but the casing can also be damaged in the process. Second, the odds that the firing pin will strike exactly the same location again are very long. Third, assuming one uses the same gun he used to fire the ammunition the first time with identical firing pin geometry, and should the firing pin precisely strike the exact same indent it left from the first firing, the odds are the round will still fire. That’s an acceptable gamble in most all scenarios except self-defense.

A small base funnel and a powder dipper are also provided in the kit. The small base funnel is used to charge the cases with primer and powder. The powder dipper has a small cup on either end that provides a precise powder measure with each dip. Weighing the powder charge is unnecessary if you use the powder dipper and follow the instruction book.

A pliers-like tool serves double duty as a two-cavity bullet mold and crimping tool. Two bullets can be made per cast; one is a 25-grain solid point, and the other is a 38-grain round nose. Sharp Shooter’s plier mold has a steel spur cutter engineered into the mold that flat cuts the bullet’s base. The bullets, themselves, have a lube groove cast into them for proper down-bore bullet lubrication. Bullet lubrication compound is commercially available, but alternatives like beeswax will work. Unlubed bullets are safe to use, but they will result in lead accumulation in the bore, necessitating frequent cleaning.

Resizing expended brass casing before reloading is a good idea but not necessary if the reloads are fired in the same gun. If the intention is to use the reloaded ammunition in several different guns, resizing is necessary. Sold separately, Sharp Shooter offers an inexpensive resizing die that fits any sin-gle-stage reloading press.

Casting your own bullets does not require using a casting furnace or buying lead. Almost any old iron pan or pot will work, and it can be heated using a propane blowtorch or other gas-type burner. Lead is available from numerous sources. Wheel weights, recovered lead shot or bullets can all be melted for bullet casting. Slag can be skimmed off using an old spoon. Preheating the mold prior to lead casting is important to flawless bullet casting. Be sure to extend the bullet mold’s handle length with a vice-grip or suitable locking pliers and wear gloves and eye protection. It’s also wise to do all lead melting and casting outdoors. Wearing a breathing mask is also a good idea.

Follow Directions

Make no mistake, reloading rimfire cartridges is a time-consuming process. Follow the provided instructions carefully. The most important step (before priming) is meticulously scraping the burned primer residue out of the inside rim of each cartridge case. That narrow little rim space must be clean so new primer can be worked into the rim.

Once the cartridge cases are primed and dried and bullets are cast, the next step is charging them with powder. Sharp Shooter’s instruction book provides suggested charge guidelines for several commonly available smokeless gunpowder brands, e.g., IMR, Hodgdon, Alliant Unique and Pyrodex P. Additionally, black powder can be effectively used.

The small powder funnel provided in the kit is used to charge each casing. The .22 bullets are inserted manually but need to be crimped using the bullet mold crimp-ing tool. The crimping notch is located forward of the two bullet cavities. At the conclusion of the described preceding process, the reloads are now complete and ready to shoot.

Is reloading .22 rimfire worth it? You be the judge. If history repeats itself, there will be future ammunition shortages. Having this inexpensive reloading capability in your hip pocket is insurance from tyranny. Sharp Shooter’s products work as advertised.

The U.S. Office of Strategic Services (OSS) used flechettes in mini crossbows and handgun spigot launchers. Spigot launchers were a device that went on the muzzle of the M1911A1 pistol, rather like a rifle grenade launcher. A rod acted as the firing pin extension to transfer the blow to the primer in the device. The cartridge was self-contained, as ignition drove a piston which did not leave the cartridge case, thereby containing the expanding powder gasses so that the cartridge produced little noise. The piston drove a big flechette ahead of it, which shot from the launcher as a projectile dragging the cartridge case with it.

The big flechette had enormous killing power due to its size, which was important when only one shot can be made. The large flechette was more deadly than a small caliber handgun but produced similar or audible less report. This made the spigot launcher a single-shot weapon of great value for covert assassinations where the sound of a gun firing could alert the enemy forces and hinder escape.

This system was used in Vietnam with Smith & Wesson .44 Magnum revolvers bored out to accept this sort of cartridge except that in these, the piston drove a conventional bullet out ahead of it. In these, the case stayed in the gun. These were well appreciated by the “tunnel rats” who had to fire in tightly confined spaces where the noise of a normal gun was greatly magnified to a permanently deafening level. A silent weapon was a necessity if you wanted to avoid deafness. The U.S. Navy also had a revolver firing one large flechette on this principle for underwater use. The Russians copied this design to work with smaller cartridges in a compact automatic pistol also adapted the design for use in an underwater gun.

The need for an improved cannister round for tank guns led to research in flechettes loaded in artillery shells as an alternative. This research bore much fruit during the Vietnam War when flechettes were used in 12-gauge shotguns, 40 mm grenade launchers, 2.75-inch and 5-inch aircraft rockets, 81 mm riverine mortars, 90 mm and 106 mm recoilless rifles, 105 mm howitzers, 120 mm cannon, and in 90 mm, 105 mm, and 152 mm tank guns.

Anti-war protestors, championing the communist side in the Vietnam War, attacked the use of flechettes vehemently as these munitions were devastating to the communist forces attacking American soldiers. The political pressure they brought to bear resulted in a decline in the fielding of flechette systems, which left American forces more vulnerable to communist human wave assaults.

Today, Israel makes a copy of the U.S. 105 mm tank flechette round and both Russia and China reportedly maintaining large inventories of flechette ammunition for their major caliber artillery.

Current U.S. fielded flechette munitions include the 70 mm Hydra rocket (a modernized version of the 2.75-inch rocket), 84 mm Carl Gustov recoilless rifle munitions, and classified defense systems. Both the 70 mm Hydra rocket and the 84 mm Carl Gustov recoilless rifle flechette loads have been used in the Global War on Terror that began in 2001.

FLECHETTE SHOTGUN SHELLS

The use of flechettes in shotgun shells is the most common small arms employment of flechettes and the application of most interest to civilians. Credit for being the first to apply this concept to small arms goes to Irwin R. Barr of Aircraft Armament Co. in the early 1950’s. Originally, the idea was for one flechette per round and this led to the Army’s SPIW program. The first shotgun shells were loaded in 1953. These 32 flechettes-per-round loads were of a smaller size than those of today.

During the Vietnam War, flechette-loaded shotgun shells made kills out to 100 yards, proving their worth as a military weapon. Whirlpool Corporation had done development work on them, also loading many shells. Federal Ammunition made them, loading 25 flechettes per round while Western Cartridge Company’s load held 20 flechettes per round. Both of these rounds had their flechettes in a plastic cup buffered with granulated white polyurethane powder to maintain bore alignment. There was a metal disk at the rear of the cup the prevented the wad from being driven through the sharp tail fins of the flechettes. The tips of the flechettes were exposed and were visible at the mouth of the cartridge case These rounds would ruin a choke if fired through one, and they were only used in cylinder bore riot guns.

SPECIFICATIONS

Sometimes at gun shows, I have seen shotgun shells loaded with surplus artillery flechettes. Typically, some are loaded forwards and some backwards. Do not fire these in anything. They will tear up the inside of a shotgun barrel, as the hard steel of the flechettes will plow furrows in the bore and destroy any choke that gets in their way.

Properly loaded flechette shotgun shells are available from Sabot Designs LLC. The current loads are safe to use in any shotgun and will not hurt even a full choke, as the bore and choke are protected from the hard steel flechettes by a patented sabot that prevents any metal-on-metal contact. This was the invention of the firm’s oner, John Flannigan, and enables them to be used in any shotgun, not just cylinder bored riot guns.

Considered by many to be the greatest expert in flechette design and manufacture, much of Flannigan’s work remains classified, but what we can divulge is impressive. He made experimental tantalum flechettes for the Naval Surface Warfare Center’s Cargo Round. He designed and manufactured tungsten flechettes for the NSWC EMRG electro-magnetic rail gun sub-munition. His collaboration with General Dynamics Ordnance and Tactical Systems on the development and testing of the “High Density Packing” (HDP) cannister for the M1 Abrams tank resulted in his patent for the HDP Cannister round. Lockheed-Martin engaged him as a consultant for the fin design of the flechette projectiles for the Hydra-7 mine clearing system. The Marines Corps had him develop a flechette round for shooting down drones. That’s about all that we are free to talk about though.

FLECHETTES COMPARED TO BUCKSHOT

Comparing flechettes to the old standard, buckshot, reveals the strengths and weaknesses of both. Buckshot depends on its size, weight, and momentum to produce casualties. Of all projectiles, buckshot’s round ball deflects the least when hitting foliage and twigs. For this reason, it was often favored in jungle encounters.

Flechettes have 211% more projectiles per shell than buckshot which greatly increases the chance of a hit at longer ranges. They have 19 projectiles compared to just nine in the military buckshot load. Flechettes are a near perfect aerodynamic shape, whereas the round ball is the least aerodynamic. Furthermore, lead balls tend to deform when fired so they are not even perfectly round anymore. At longer ranges this becomes more of a factor. Additionally, flechette loads weigh about half as much as an equivalent buckshot load, so combatants can carry more ammo into the fight.

The stopping power of flechettes is a result of their velocity, penetration, and energy. Each flechette has the same energy signature as a 9 mm Parabellum round. It will shoot through a car door and produce a casualty on the other side, or it will go through over 20 inches of ballistic gelatin. Its energy is transmitted to a casualty by creating a supersonic cavitation wound channel. It will yaw off course as it penetrates, creating a wound channel approximately 800% larger than the flechette. This averages about .58 caliber for each flechette. Flechettes may also bend or break, creating secondary wound channels. They also typically shatter bones on contact.

ENGAGEMENT RANGES

* This being the longest range that a single flechette will produce a casualty.

CIVILIAN USE

12-gauge shotgun flechette loads are extremely useful to civilians. I’ve heard of a person taking out the heart and lungs of a wild hog at seven yards that was chasing and about to overtake his friend. Flechettes will penetrate the thick skull of an enraged bull or a 1000-pound hog when buckshot may fail. Flechettes have proven effective on deer, turkey, wild hog, and bear and are earning a devoted following among hunters. People depending on a shotgun for home defense are looking to flechette rounds for increased effectiveness.

Ever since the American Derringer Co. first invented the pistol chambering both the .45 Colt and the 2.5-inch .410 shotgun shell in 1980, there have been more companies making pistols that chamber these rounds interchangeably. Sabot designs makes a 2.5-inch .410 flechette load with seven flechettes for these.

Standard flechette rounds may not function reliably in automatic shotguns. Rounds that will reliably function a semi-auto are available under special order from Sabot Designs LLC.

Like birdshot, slugs, and buckshot, the flechette shotgun load has taken its place among the standard loads available for shotguns today.

“Following its initial release, Federal Fusion ammunition quickly gained a reputation for its exceptional performance and reliability,” said Eric Miller, Federal’s Centerfire Product Line Manager. “Over the past 18 years, we have expanded Fusion into a large list of calibers and bullet weights, now totaling more than 50 product offerings across three different product families. This has allowed hunters and shooters to experience the benefits of bonded-core technology across a broad spectrum of firearms and game species.”

“Rifle ammunition featuring polymer tips is nothing new. Yet it has revolutionized the shooting industry with its innovative design and exceptional performance,” said Jake Burns, Federal’s Centerfire Rifle Engineering Manager. “The aerodynamic properties of polymer-tipped rifle ammunition contribute to improved flight characteristics and stability. This feature is especially valuable for long-range shooting, where maintaining stability and accuracy over varying environmental conditions is essential.”

According to Miller and Burns, the all-new Fusion Tipped design offers the same great terminal performance as the original, but with a polymer tip that reduces wind drift and drop, as well as delivering more energy downrange. Paired with a skived nose cavity, the polymer tip also helps initiate consistent, lethal expansion. All this increases ballistic coefficient, flattens trajectories, and boosts energy for better accuracy and extended effective range.

The all-new Fusion Tipped initial offerings will include 300 BLK 190-grain, 6.5 PRC 140-grain, 6.5 Creedmoor 140-grain, 270 Win. 150-grain, 7MM Rem. Mag. 175-grain, 7MM PRC 175-grain, 308 Win. 180-grain, 30-06 Sprg. 180-grain, and 300 Win. Mag. 180-grain. Its 20-count boxes range in price from $44.99 to $81.99 depending on cartridge choice.

For more information on all products from Federal or to shop online, visit www.federalpremium.com.

Due in part to the growing cost and dwindling availability of Class III machine guns and suppressors, considerable interest has shifted to 37mm and 40mm launchers; now there are several options. One of the most popular is the underbarrel M203- type for mounting on a rail under a M16/AR-15 rifle. The underbarrel launchers are available in both 37mm and 40mm. There are also stand-alone models, as well as the old 38mm Federal Laboratories launchers used by police. Original GI and aftermarket 40mm M79 grenade launchers occasionally are offered for sale, and Spike’s Tactical now offers an accurate replica of the U.S. M79 launcher in unrestricted 37mm. 

For those considering the purchase of a launcher, the number one question that arises is, “What can I legally fire from the devices?” Well, much depends on the status of the launcher. 

Most 37mm launchers are primarily designed to launch flares, signal, smoke and other non-lethal rounds. 

Launcher Rounds 

Like the 37mm, 40mm launchers can fire flares and smoke, but 37mm and 40mm launchers registered with ATF as “destructive devices” can also shoot buckshot, flechettes, batons, rubber pellets, bean bags and other anti-personnel rounds. HE (high explosive) rounds are unavailable to the general public; if available, each round is considered a destructive device itself and would require a $200.00 tax per round; they also require a Federal Explosive permit and fall under strict shipping and storage guidelines. 

The definition of a “destructive device” is found in 26 U.S.C. § 5845(f). The definition reads as follows: 

(1) any explosive, incendiary or poison gas, (A) bomb, (B) grenade, (C) rocket having a propellant charge of more than 4 ounces, (D) missile having an explosive charge of more than 1/4 ounce, (E) mine or (F) similar device; 

(2) any weapon by whatever name known which will, or which may be readily converted to, expel a projectile by the action of an explosive or other propellant, the barrel or barrels of which have a bore of more than one-half inch in diameter, except a shotgun or shotgun shell which the Secretary finds is generally recognized as particularly suitable for sporting purposes; and 

(3) any combination of parts either designed or intended for use in converting any device into a destructive device as defined in subparagraphs (1) and (2) and from which a destructive device may be readily assembled. The term “destructive device” shall not include any device which is neither designed nor redesigned for use as a weapon; any device, although originally designed for use as a weapon, which is redesigned for use as a signaling, pyrotechnic, line throwing, safety or similar device; surplus ordnance sold, loaned or given by the Secretary of the Army, pursuant to the provisions of section 4684(2), 4685 or 4686 of Title 10 of the United States Code; or any other device the Secretary finds is not likely to be used as a weapon, or is an antique or is a rifle which the owner intends to use solely for sporting purposes. 

The 40mm launchers can fire the M781, GI chalk practice rounds when they can be found for sale. There are a number of different 40mm practice rounds, but the M781 round with the white nylon M212 case with a blue plastic nose cone is the most commonly available. The lift charge in the M781 cartridge is a .38 S&W BLP blank; the nose cone is filled with a bright orange powder, which is attached on a zinc pusher. Upon impact with a target, the nose cone shatters, and the powder dissipates in an orange cloud to mark where it hit. The practice rounds are designed to simulate the same ballistics as an HE round. 

Another interesting round that can be fired from registered 40mm launchers is known as the “Beehive” or “Hornet’s Nest.” The case is usually made of aluminum and holds 10 to 18 .22 rimfire cartridges, depending on the model. The .22 shells are all fired at the same time. This is accomplished by a steel disc with multiple fixed “firing pins.” The disc is actuated by a rifle primer, which thrusts the disc forward and fires the rounds. There are also 40mm shells available for simultaneously firing four .410 gauge shotgun shells. 

In addition to all the aforementioned calibers, adapters are available for both 37mm and 40mm devices to launch the surplus Czech 26.5mm or 12-gauge flares and smoke projectiles. Corrosive black powder is used as the lift charge in many 26.5mm projectiles; be sure to thoroughly clean your launcher after firing it. There are adapters available for registered launchers to fire 2 3 / 4-inch and 3-inch, 12-gauge shotgun shells. 

Loading Your Own 

There are a number of vendors that sell both loaded ammunition and kits for loading your own ammo for 37mm and 40mm launchers. The loading kits include reloadable plastic or aluminum shells, fuses and plastic or heavy rolled paper payload tubes. Rubber bands are used to assure the tubes are a tight fit inside the shell casing. The less expensive shell design uses a synthetic black powder lift charge ignited by a shotgun shell primer. The disadvantage of the black powder type is the large amount of smoke that is emitted from the muzzle, and black powder is corrosive. 

Smokeless Rounds 

The other type of shell generally uses the same plastic or paper/cardboard payload tubes, but in place of a somewhat large amount of synthetic black powder, the shell uses a small 5 to 6 grains charge of smokeless pistol powder for the lift charge and a small or large pistol primer for ignition. These shells use a similar high–low pressure system that is used in GI 40mm rounds. A copper burst disc is used to allow the pressure to build up in the high-pressure chamber until it bursts, and the pressure dissipates into the low-pressure chamber; the decreased pressure is used for launching a projectile. This type of shell produces far less smoke upon launch and has a far greater range than the black powder shells. The shells are reloadable; the downside is they are more expensive than the black powder shells, but they are built to last a lifetime. The smokeless shells are available in 37mm and 40mm. The smokeless 40mm M212-type shells can be loaded with the M79-M203 zinc pushers with a rotating band and the blue nose cones. The cones can be filled with powdered chalk normally used for chalk lines for construction projects. The chalk is available in a wide variety of colors. 

The purchasing of ready-made ammo for a 37mm or 40mm launcher can get expensive. Substantial savings can be realized by loading your own fodder. Assembling the rounds requires a few tools and supplies: a hot glue gun, rubber bands and payload tubes. Smokeless cases require: primers, a primer punch, copper sheets and a disc cutter (for making burst discs). Loading is not difficult and almost enjoyable. Most reloading kits include instructions, and a number of instructional videos can be found on YouTube. 

FOR MORE INFORMATION 

Pace Launcher Casings, LLC Reloadable 37mm and 40mm smokeless shells 

reloadableshells.com 

American Specialty Ammo Black powder shells, launchers, fuse, payload tubes 

americanspecialtyammo.com 

MLR Distributing, LLC Launchers, reloading supplies 

mlrdistributing.com 

Exotic Ammo.com (Ordnance Group LLC) Launchers, 37mm ammo, reloading supplies 

exoticammo.com 

DeGroat Tactical Armaments, LLC 40mm .22 caliber Beehive rounds 

armamentsales.com 

Spike’s Tactical Launchers 37mm and 40mm 

spikestactical.com 

Lewis Machine & Tool Co. (LMT) 40mm Launchers 

lmtdefense.com 

Grog’s 37mm and 40mm discussion forum 

37and40mikemike.com/test/index.php

With “black rifles” dominating the gun media of late it is easy to forget that other firearm types exist. My initial interest in firearms was hunting rifles typified by bolt-action rifles. Let’s continue to pull on this idea thread. What comes to mind if “bolt-action rifle” is mentioned? I would venture to say an image of a 26-inch heavy profile barrel in a stout stock appears in readers’ thoughts. .308Win/7.62 NATO is the standard chambering with the caveat that cartridges are only getting larger to provide extended range and punch. Where are we going with this? Other bolt-action rifle types exist. Sometimes exploring something different broadens your horizons. Our analysis will not be based on the military or law enforcement logistical chain; rather think more along the lines of a company satisfying a changing sporting market due to a hunting regulation change. 

Ruger as a company has proven to be versatile and adaptable. A diverse product catalogue supports this. When Michigan and other Midwestern states began amending hunting regulations to allow for straight-walled rifle cartridges with overall lengths of 1.16 inches to 1.80 inches in lieu of shotgun or muzzle loading only, manufacturers quickly answered consumer calls. The original intent was for big bore revolver cartridges such as .44Mag, .454 Casull and .500 S&W to be taken afield in rifle packages. Ruger decided that a cartridge designed to increase AR-15 potency would make a good candidate for this new role. Enter the .450 Bushmaster chambered in the bolt-action Ruger American® Rifle Ranch. 

The .450 Bushmaster 

The urge to expand AR-15-type rifles beyond .22-caliber “poodle shooters,” while maintaining ergonomics, has led to interesting cartridge creations. The .450 Bushmaster is an excellent example of this. The .450 Bushmaster was designed by the Hornady Manufacturing Company for Bushmaster Firearms when the latter wanted a .45 caliber cartridge that would work through the AR-15 action. The Bushmaster is based on a shortened .284 Winchester case. It is a rimless, straight-wall case with a rebated .473-inch diameter rim and a .500-inch-diameter head. The case is 1.70 inches long. It uses .452-inch-diameter bullets, as used in .45-caliber handguns, NOT .458-inch-diameter rifle bullets. The loaded overall cartridge length is 2.250 inches, and the case takes small rifle primers. 

Typical bullet weights range from 250 grain up to 300 grain. Hornady and Remington make several loads available for users. Buffalo Bore does offer a potent 360-grain hardcast .450 Bushmaster option along with multiple other bullet weights/types. Not a surprise to anyone familiar with Buffalo Bore’s innovative ammunition offerings. 

The .450 Bushmaster was specifically designed to generate stopping power at short to moderate ranges out of the AR. Two-hundred fifty- to 300-grain .450 Bushmaster loads pushing 2,200 feet per second with a 175-yard zero will give a relatively flat trajectory out to 200 yards; the 175-yard zero will have the bullet offset about 2 inches high at 50 yards, +3 inches at 100 yards and dropping -3 inches at 200 yards. The .450 Bushmaster’s heavy, large-diameter bullets and moderate velocities make it well-suited for use in multiple arenas not just urban/CQB environments as initially designed. .450 Bushmaster chamberings are expanding into sporting roles with bolt-action rifles coming on board to supplement AR types. The .450 Bushmaster’s terminal ballistics and large projectile have equal effect on engine block or large hog, assailants with body armor or penetrating the front chest of a bear. Automotive body panels are passed through as easy as a deer cavity. 

The .450 Bushmaster in the bolt-action Ruger American Rifle Ranch gives hunters .45-70 Government performance in a compact 36-inch, sub-6-pound rifle. The 16.12-inch cold hammer forged barrel is free-floated with muzzle brake affixed via 11/16-24 thread pattern. The muzzle brake is secured by an adjustable barrel nut in place of a crush washer. The steel receiver is topped with a factory-installed, 5-inch aluminum optics rail compatible with Picatinny-type scope mounting systems. This simplifies optic mounting and even allows for red dot use if the user desires. The single-piece, three-lug bolt cycles smoothly and features a full diameter bolt body, dual cocking cams and a round knob bolt handle. The bolt handle’s 70-degree throw keeps it clear of the optic. A three-round detachable box magazine feeds the stubby .450 Bushmaster into the chamber. A tang-mounted safety completes the action. 

Ruger uses a lightweight Flat Dark Earth synthetic stock featuring its patent-pending Power Bedding integral bedding block system, which gets the most of accuracy potential. A Ruger Marksman adjustable single-stage trigger set at 4 pounds further assists in the accuracy equation. The trigger is the interface between shooter and rifle in terms of producing accurate shot placement. Yes, the shooting position and way the rifle is mounted is important; however, the trigger press has the last word in terms of sending a round down range. The goal is to minimize shooter input/energy at the time the shot is taken. 

Good marksmanship in the field starts with confidence. Confidence is built through firing a rifle that is not overly punishing and is inherently accurate as demonstrated from the bench. Each of us has different standards and tolerances with this. A rifle that shoots well off the bench offers the shooter no excuses or alibis when serious practice includes field shooting positions or shooting in the woods. The Ruger American Rifle Ranch .450 Bushmaster with a Burris RT-6 1-6x24mm optic produced consistent 1.50-inch or better groups at 100 yards. Hard to ask for more than this from a compact economical bolt-action with a 1-6x power scope on board. 

Testing

The Ruger American Rifle Ranch with its portability is intended for stalk or still hunting forays. This translates into fluid off-hand shots at game and not off rests or bipods—if lucky, the hunter will be able to adopt a kneeling or sitting position in lieu of off-hand shooting This was simulated during a T&E at Echo Valley Training Center (EVTC) by setting up clay pi-geons at various ranges and then assuming sit-ting, kneeling or standing shooting positions. Another twist is to have a companion pick the target and shooting position and the shooter to engage as designated as quickly as possible. Further field testing consisted of EVTC’s Jungle Walk Range. The ability to move through its varied terrain and engage randomly placed deer targets hidden within cover suited the Ruger American Rifle Ranch .450 Bushmaster evaluation perfectly. Ranges involved were 35 to 150 yards with multiple shots fired at most of the targets. The emphasis was on accurate shot placement and working the Ruger American’s bolt without removing the rifle from the shoulder. The low 1x setting on the Burris RT-6 allowed for a wide field of view and quick target assessment/engagement. A quick crank of the magnification knob allowed for easy targeting of longer range targets. The Ruger stock and recoil pad combined with muzzle brake tamed recoil to manageable levels even with the stout Buffalo Bore rounds. The Ruger American Rifle Ranch proved to “hang” well and was very manageable in getting into and out of field shooting positions. While not empirical data, the muzzle brake on the Ruger American tames felt recoil into about the 28/20-gauge shotgun realm for reference sake. This encourages more range time, equating to increased proficiency. 

For Use Anywhere 

The Ruger American Rifle Ranch .450 Bushmaster’s appeal is not confined to only the newly opened areas of Michigan and other Midwestern states. In steep, thick terrain, i.e., Appalachian Mountains or southern swamps, game needs to be anchored quickly. A wounded animal will inevitably head downhill or the toward the most inconvenient direction, often causing a lot of extra work to extract it once recovered. The quick-handling, heavy-hitting Ruger American Rifle Ranch chambered in .450 Bushmaster is ideal for this environment, too. 

FOR MORE INFORMATION 

Ruger 

ruger.com 

Buffalo Bore Ammunition 

buffalobore.com 

Burris Optics 

burrisoptics.com 

Hornady Manufacturing 

hornady.com 

Remington Ammunition 

remington.com/ammunition 

SIG SAUER 

sigsauer.com 

Echo Valley Training Center 

echovalleytraining.com 

“We are proud to provide the highest quality duty ammunition to CBP officers charged with the monumental task of border security,” said Federal Ammunition President and CEO Jason Vanderbrink. “We know they require the best ammunition in their mission to protect our borders and keep the homeland safe. This large duty contract win solidifies Federal Ammunition as a top choice for law enforcement.”

The cartridge selected was the Tactical Bonded 64-grain soft point. This single-award, Indefinite Delivery Indefinite Quantity contract is a Strategically Sourced contract for all DHS components with a maximum quantity of 143 million rounds. The ordering period is for a total of five years.

“Federal’s Tactical Bonded line is a trusted partner for some of the most intense conditions,” said VP of Law Enforcement Sales Dave Leis. “Made exclusively for law enforcement and at our Anoka, MN headquarters, it achieves accuracy and terminal performance that defeats tough barriers with minimal change to its superior performance attributes.”

In 2019, Global Ordnance introduced its CanMunition™ line of 9mm Luger and 5.56mm Remington ammo packed in what looks like a soft drink can. Holding approximately 90 pistol cartridges or 40 rifle rounds, these nitrogen-filled cans have a wide pull-tab covering the entire top of the container. A snap-on, black plastic lid guards against accidental opening. The 5.56mm selected is 55-grain Fiocchi boat tail ball, a very consistent and reliable load. The 9mm is also by Fiocchi, a 115-grain ball cartridge. 

Ammunition in sealed “spam” cans has been around at least since before WWII. American shooters are mostly familiar with the thick Soviet cans holding 440 or 880 rifle rounds, but other sizes have been popular as well. Bulgaria packed them in lots of 250; Serbia in lots of 800 or 1,000, but all of these long storage containers were meant for regimental use. The tins were bulky and usually required a tool to open, but they did fill the purpose of keeping the contents dry and clean. The countries that failed to figure out how to store ammunition properly, like Turkey and India, got the reputation for very questionable surplus. More recently, lighter plastic packaging has been developed to the same purpose, proving adequate for keeping humidity out but not for mechanical protection of the contents. CanMunition aimed to provide long-term storage without sacrificing the expediency of access, and in lots small enough to be portable. 

The most recent run on ammunition culminated in distributors being out of the most common calibers less than a week after it began. Compared to the early 2000s, the availability of military surplus ammunition declined sharply because of the EU directive to destroy surplus instead of selling it. Anticipating this kind of problem, many prudent people stocked up on gun-food well in advance. Some have discovered that humidity, temperature fluctuations and other eventualities of storage resulted in the deterioration of the cache much sooner than expected. Cardboard packaging absorbing atmospheric humidity is one noted offender. Do CanMunition containers work better?

In most ways, yes. Nitrogen keeps rust and verdigris at bay quite effectively. The 40-round rifle ammo can weighs 18 ounces; the 90-round 9mm can is much heftier at 38 ounces. Either can be handled with ease. The tightly packed contents keep the thin aluminum of the container from deforming easily. The cans themselves have little thermal mass, and they provide minimal insulation from temperature fluctuations. One way to keep them at a relatively constant temperature in a hot car is to place them in a plastic cooler, arranged in a checkerboard pattern with water bottles acting both as a thermal sink and as an emergency liquid supply. If freezing temperatures can be reasonably expected, non-liquid heat sinks are preferred. The cartridges can be cold without ill effect, but avoiding sharp temperature rise is key. When shipped, the cans arrive wrapped in thick paper and enclosed in sealed cardboard boxes, providing some measure of thermal insulation.

Besides the obvious storage utility, these cans make great gifts. Everything, from the humorously ominous graphics on the can to the suitability for long-term retention, makes the cans not just a cute idea but also a very good one. The shelf life can be several decades, though it’s best if the oldest ammunition in the stash is rotated into use as newer stores are acquired. Needless to say, I’ve had zero problems with the contents when several hundred rounds of each caliber were put to use. 

In the sixth year of the War, the resources of the German Reich had become scarce. How practical would it be to fire two bullets with one cartridge? This idea woke the interest of the Waffen-SS. 

By the end of 1944, the German Armed Forces (apart from the numerous captured weapons) mainly used two types of rifle cartridges:

• 7.92x57mm with s.S. (heavy spitzer) bullet for rifles and machine guns
• 7.92x33mm kurz with the short Mkb bullet for machine gun carbines/ assault rifles

In order to make the cartridges more effective, a large number of other bullets, such as tracer, hard core or even explosive projectiles, were put in the cases.

Another way to increase cartridge performance was chosen in autumn 1944: If two bullets could be put in a single cartridge case, the double effect on the target could be achieved simultaneously with savings on raw material, weight and transport space without additional training for the soldiers. On the weapons themselves, nothing would have to be changed. With the loss of territory in the east, the ongoing supply of the necessary raw materials for the armaments industry partially dried up, and the air raids on the Reich further reduced the already scarce transport space.

Experimentation

The idea of putting two bullets in one case sounded simple. But the devil was in the details. The experiments with different bullets and powder types dragged on for a long time. In addition to the Heereswaffenamt (Army Ordnance Office), the SS ordnance office department “Research, Development Patents” (FEP for short), headed by SS-Gruppenführer Dr.-Ing. Otto Schwab, was involved in it. Some of the test firing attempts took place at the Gottow shooting range, which was part of the Kummersdorf Army testing institute and was officially named “Wa Prüf 11—Special Equipment Department.”

The experiments started with two bullets, 123.5 grains each (8g each), of the standard rifle cartridge in a case with a 24.7-grain (1.6g) powder charge. During a test with three rounds, under the direction of SS-Untersturmführer Winzer, a very large dispersion was noticed at a distance of 30m. The last shot got stuck in the barrel. Increasing the load to 37 grains (2g) brought little improvement. Also, in this case, bullets got stuck in the barrel. Two Mkb bullets were then put in the case, and the charge was increased to 37.037 grains (2.4g). With 16 rounds fired, the result was satisfactory. There were no outliers, and no bullets got stuck in the barrel.

Now it was time to increase the distance. For the next attempts, the target was hung at 100m. The case with the two Mkb bullets was filled with a main charge of 24.7 grains (1.6g) and an additional front charge of 1.23 grains (0.8g). The accuracy was again satisfactory with an average of nine rings per round. So far, so good, but the trajectory no longer matched the sights of the weapons. Calculations showed that the speed of the shorter Mkb bullets had to be increased from 665m/sec to 750m/sec.

Detailed investigations also showed that the second bullet flew in the slipstream of the first bullet and thus in a zone of reduced pressure. This resulted in a fairly constant deviation from the trajectory of the first bullet. In the meantime, it was January 1945, and the SS put the team under pressure. The SS ordnance office therefore contacted the Finower Industrie GmbH, which, as an experienced manufacturer of infantry ammunition, was to make the double-bullet cartridges ready for series production. Two SS technicians from FEP were assigned to Finower for this purpose. The best results were achieved with a cartridge containing one heavy bullet 193.7 grains (12.55g) and behind it a shorter and lighter Mkb bullet. At the beginning of February, it was clear that “the characteristics of this new type of infantry ammunition have been clearly recognized by extensive tests and that special manufacturing difficulties are not to be expected.” The Heereswaffenamt successfully carried out a mass firing test with these cartridges.

Before the new ammunition could go into series production, there was a meeting in Friedenthal near Oranienburg on March 17, 1945. The illustrious group counted many well-known names, such as SS-Standartenführer Dr. Heeß (Institute for Criminal Technology RSHA) and SS-Obersturmbannführer Otto Skorzeny (Unit I B Friedenthal). Plant manager Eibl explained that the double-bullet cartridge weighed 445.2 grains (28.85g), in contrast to the normal s.S. cartridge weighing 419.8 grains (27.20g). A cartridge with two bullets saves 158.2 grains (10.25g) on the case and 53.24 grains (3.45g) on the powder compared to two normal cartridges, without reducing the combat effect on the target and without putting more strain on weapon mechanics. Test firing with the machine gun MG42 was successful.

SS-Untersturmführer Schürmann of the SS-paratroopers praised the development and agreed to order 15,000 cartridges for the special infantry battalion Friedenthal (named after the castle Friedenthal). However, the delivery was initially to be seen as an “emergency solution” without special requirements at any point in the manufacturing process, and any problems that might occur were accepted. The main thing was that the cartridges could be delivered as quickly as possible. It is unclear whether and where production actually started. Reports or other evidence of use in action are not known. In any case, all cartridge production in Finower ended due to a lack of raw materials in March 1945.

On April 25, 1945, the SS-FHA T-Office (SS-Führungshauptamt Technical-Office, SS-FHA’s main operational department), which had meanwhile relocated from the encircled capital Berlin to Dachau in Bavaria, discussed the future manufacturing options. Since there were no suitable factories in the still unoccupied part of Bavaria, production would begin in Italy, the Protectorate or Tyrol. The Austrian inspector for armament and equipment in Salzburg would explore new companies and workshops. But ultimately, nothing came of it. In May, the War was finally over in Europe. 

Reloading—taking a fired cartridge case, reforming it, replacing the primer, powder and bullet, and shooting it again. Most folks do not know that reloading was first widespread by the U.S. Army. As always, logistics was a big issue after the Civil War, with the adoption of the breech-loading rifle. Our first breechloaders were muzzleloaders, converted to load from the back. As they were issued out to the troops on the Western frontier, resupply from the East (St. Louis) took time.

As a result, some ordnance officer, whose name is lost to history, figured out that it took less space to ship lead bars, kegs of powder, primers and one set of reloading tools than case after case of ammunition. The ordnance folks always want to save money, so recycling the cases (in the recycled guns) was a good idea. When you get supplies perhaps once a month—IF the wagons got through—running out of ammo is not an option. 

How Is It Done?

These days, the reloading process is pretty much the same as it was in the 1870s. Obtain some cases; clean them; reshape the case; remove the old primer; place a new primer; add a measured powder charge; place the bullet in the case; fire the round again. It is cost-effective—about half the cost of factory ammo. But here is the secret the folks who make reloading tools don’t talk about: You don’t save any money! You shoot twice as much!

Yup, for the price of 50 rounds of ammo, you now have 100! Yee Haw! As this is written, guns and ammo are disappearing from gun shops so fast that most shops limit how much you can buy; maybe 1 or 2 boxes! They make toilet paper seem to be readily available! While the components can be hard to find, they are out there and still cheaper than factory ammo.

Reloading is efficient—in addition to expanding your ammo per dollar, it does not take much time. Even with a single-station press that does one operation at a time, by loading in batches you will never miss a practice session, match or hunt because you do not have any ammo. If it’s too cold, hot or wet to go shooting (it’s hard to believe, but some folks feel that way), you can always load some more ammo!

Fun? That too! When the author has a knotty problem to work out or is irritated about something, he’ll start focusing on loading some ammo and usually work out an answer or work off irritation and get a better perspective on things. Plus, one gets to fine tune the load for his or her particular firearm and objective. There is personal satisfaction at making that difficult shot with ammunition you built yourself. When the steel “clangs” at over 1,000 yards, or the holes in a target are all tightly grouped, there is extra pride in knowing YOU made those rounds.

Increase Your Versatility 

Do you want to introduce someone new to shooting? Load up some reduced charges for less blast and recoil, so they can focus on the fundamentals. Want to see how accurate a rifle or pistol is? Try different loads to find that sweet spot of maximum accuracy. It’s all there to experiment with. There are folks who buy a box or more of every brand of ammunition in their preferred bullet weight in their chosen caliber and then spend hours carefully trying to figure out which is the most accurate in their rifle or pistol. They end up spending a lot of money creating an inventory of partial boxes of ammo that are inaccurate for their purpose.

A reloader can choose a bullet weight and powder and then load a few rounds with each of several different powder charges and in one range session figure out what load works best in his/her firearm. They can try different brands of powder and bullets by different makers to see the effect on their group size. If the finest precision is their pursuit, they can then further refine their load, until every shot goes into a tiny group. Others want a capable load at the least expense so they can produce lots of ammo for practice and/or competition. Shooting is a perishable skill, and practice is the key to skill maintenance and enhancement.

Then there are those fascinated by older guns in calibers no longer produced. A reloader can obtain the necessary dies to load just about anything, so that antique family heirloom can go out to the range and let its owner feel what it was like “back in the day.” There are even ways to make cartridge cases from existing models to revitalize that oddball round.

Our focus will be on rifle and pistol ammunition, as reloading shotgun shells is not as cost-effective. Of course, for some bird hunters and shotgun sports competitors, the sheer volume of shooting brings on economies of scale, justifying reloading their hulls.

Some of the readers own full-auto firearms, and the days of inexpensive bulk surplus ammo are long gone. But you can keep those hungry guns fed by reloading. In fact, one reloading tool company was founded because the inventor wanted to shoot his machine guns more than his budget could allow!

Whatever your shooting goals—excellence in competition, meat in the freezer or shooting some gun in an obsolete caliber—learning to reload opens new vistas for the hobbyist, collector or general gun owner.

Getting Started

There are some upfront costs to be considered. These are one-time costs for the tools needed: mainly, reloading manuals; a means of cleaning the cases; a press for reforming the cases and seating the bullets; the dies for your caliber(s); a powder measure to dispense the charges of powder; and a scale to measure the charge weight. There are ways to save money here as used equipment shows up in gun shops, and almost all of it has more life left. It is not uncommon to see presses from the ‘50s still turning out quality ammo.

One decision to be made early on is how much shooting you do or will want to do. Most folks start out with a single-station press, meaning it allows one operation at a time, with the dies changed between operations. Large volume shooters may choose to dive in with a progressive press—a manually operated press that, once fed cases, primers, powder and bullets, will produce a round for every pull of the handle. Rates of 300 to 600 rounds per hour are easily attained if you have settled on one particular load.

One of the oddities of reloading is the multiple ways to get the job done. For every operation in reloading, you can find multiple ways to do it. You will prefer some and discard others, depending on the degree of precision you desire, the volume of ammunition you want to shoot and the differing calibers you may want to reload.

COMPONENTS

Cases

Cases are the best starting point, as they hold the other components together. They can be made of brass, steel, aluminum or plastic. With a sole exception, the steel cases are not reloadable. One company makes a case of stainless steel and aluminum which can be reloaded using special tools. Aluminum and plastic cases are not reloadable. Considering the stresses of high pressures, heat and rough handling, brass has proven to be the best material for reloadable cases. 

There are three principal sources of cases—new unloaded cases, the cases from factory ammunition and “range pickup” cases. Those shooting either in high-end competitions at the highest levels or trying to put every bullet through the same hole will buy bags of cases direct from the makers. They will track the number of times the cases are reloaded and trimmed (more about this later) and discard them at a given point. This is the most expensive source. If you have been shooting factory-loaded ammunition, you have “once-fired” brass, all from the same lot; that would be a remarkably close match to the “from the maker” brass. You have already paid for it, so your additional cost is zero.

Most shooters use range pickup brass—which is exactly what it sounds like. Range pickup brass is usually free or can be purchased for a very nominal cost, but there are some disadvantages. It will not be as uniform if absolute precision is your goal; it may have sand, dirt and/or rocks in it. It will need to be sorted in a general way for two specific issues: primer type and origin.

Europe adopted a primer type developed by U.S. General Berdan, where the anvil is part of the case. These have two flash holes inside the case, offset from the center. They can be reloaded, but it is a very messy and slow job, perfected by Europeans with depriming, using hydraulic or pneumatic pressure. Unless it is in a rare caliber, like 7.62×45, it is not worth the trouble. The U.S. adopted a primer system invented by Edward Mounier Boxer, where the anvil is part of the primer, and the case has a central flash hole. These are easy to de-prime, and most are suitable for reloading.

As you gather the brass, once you identify any brass with the Berdan priming, look at the headstamp—the markings on the base of the cartridge. It is simple enough to discard all the cases with that headstamp. As you look at the headstamp, look to see if the caliber is marked there. Commercial brass will always have the caliber, the name or initials of the maker or some other distinguishing mark. There are several books cataloging makers’ marks if interested. If the case is a military origin, there will be no caliber marking, but usually two digits for the year and a letter or number maker code. If it was made to NATO standards, it will have a circle with a cross in it, the NATO symbol.

What is the difference in the brass? Military brass is usually thicker to withstand the rough handling in the gun of fully automatic fire. As a result, it has less interior volume and can generate higher pressures than the same load in commercial brass.

As you pick up the brass, shake it in your hand. If you hear a high musical note, there is one or more cracked cases in that group. Discard all cracked cases, even if the crack is tiny and just in the mouth of the case. The crack could allow the bullet to seat too deeply during the loading cycle, massively increasing the pressure—perhaps to unsafe levels. You will also need to sort the brass by caliber—remove the .380 brass from the 9mm, 8mm from .30-06, .38 SPL from the .357 Magnum, etc. They can look the same but be very different. Continue to check the brass every time you handle it, weeding out the wrong and cracked cases.

The next step in processing the brass is to clean it—no matter the source. The author had some “fresh from the maker” brass, which still had some oil on it from the manufacturing process. Even the first round fired in your clean gun needs to be cleaned, as some of the products of combustion will cover the exterior of the case. You can use a rotary tumbler, a vibratory cleaner or an ultrasonic bath, each with advantages and disadvantages.

Primers

Primers are the ignition tools for ammunition. They contain a tiny amount of an impact-sensitive explosive, which shoots sparks into the powder charge, which then burns. Primers come in two sizes, large and small, in two types, rifle and pistol, and a variety of special uses—regular, magnum, Match, Benchrest and others.

The large and small deal with the size of the primer. In pistols, large cases usually take large primers, which contain more priming compound to set off the large powder charges. Rounds such as .44 Special, .44 Magnum, .45 ACP or .45 “Long” Colt take large primers. 9mm, .38 Special, .357 Magnum and the like take small primers. Your reloading manual will direct which size you need.

Some powders have deterrent coatings to slow the burn rate and take Magnum primers to insure uniform ignition. Again, the loading tables will note which kind of primers were used for which powders. The Match and benchrest primers are made with closer tolerances and greater uniformity and generally cost more.

Both rifle and pistol primers are the same size in large and small. In order to avoid confusion, the author uses one make with nickel-plated cups for rifle loads and a different make with copper-colored cups for pistol loads. The cups for rifle loads are thicker, to withstand the high pressures in rifles. Loading a rifle primer into a pistol case may cause a misfire. Loading a pistol primer into a rifle case may result in a pierced primer and all that high-pressure gas flowing into the action of your rifle and into your face—definitely NOT RECOMMENDED! 

Where I’ve Been and Where I’m Going

The author began reloading in the 1960s and continues to reload about 10,000 rounds per year. He loads for 16 different calibers (both rifle and pistol) on both single-station and progressive tools. He has been a professional reloader and is an NRA-certified reloading instructor. His next Small Arms Review installment will cover powders, bullet selection and putting it all together!