Bob Swinney wrote in message ...
Hey Ed,

I would like to know how the old timers made round ball cherrys for bullet
molds. Did they form the cutting surfaces with files? It seems that one
should be able to do this with W-1 tool steel.

Bob Swinney

Here's a clip from "The Gunsmith's Manual" by Stelle & Harrison originally
published in 1883.

It describes cutting the blank and filing the teeth. It goes into more depth
about filing the teeth and hardening, but I only have so much patience for
scanning.
Buy your own copy.

Paul K. Dickman

THE GUNSMITH'S MANUAL.
the operation: A rotating body is passed through a properly -shaped circular
aperture ill a flat steel die that is held with its upper or cutting in the
same plane as the axial line of the body rotating. That's all.
Now , to make application of the rule. Suppose we have a rifle of a certain
bore to which is to be fitted a round ball. First, take a piece of steel, we
will say about one-quarter of an inch thick, about one inch wide and about
six or eight inches long. An old file of good quality, with the temper drawn
and the teeth ground away, may answer the purpose. It should be annealed as
soft as possible.

With a drill make a hole near one end, but a little less in size than the
bullet to be produced. With a taper half-round reamer cut out the hole until
that side of it which is to be the upper or cutting edge is exactly the size
of the bullet desired.
The advantage of using this taper half- round reamer is the hole is made
perfectly round, and at the same time the taper of the reamer gives a bevel
to the hole that forming a good, strong and effective cutting edge. With a
file cut out & portion of the tool of a V shape, beveling the edges the same
as the hole as shown in Fig. 67. This V may be either cut on the end, a side
of the tool, as shown, but in use it is preferred to be cut on the side, as
then, if necessary, the hand can find a hold on that end to assist it in
operating. When done, temper for use. For the cherry , turn a piece of steel
in the lathe to fit a chuck. Half-inch octagon is perhaps the best size of
steel from which to make cherries of less diameter than half-inch, and the
length about six inches. The end on which the cherry is to be made , is
roughly fashioned into a ball, leaving the end I where the centre supports
it to be removed by the I lathe tool or by filing.

When fitted so that the rough blank will be held firmly in the chuck, run
the lathe at moderate speed, set the T rest so that the steel die can be
held on it about level with the under side of the rotating blank. On the
rest lay the die, and press the opening so as to receive the rough sphere,
applying oil and not pressing too hard. Let it gradually scrape its way
through the circular aperture, the V-shaped opening in the side receiving
the stem to which the cherry is attached. In Fig. 68 is shown the finished
blank after being passed through the die. If it be preferred the die may be
held in the hands and not supported on the T rest. Take care to supply
plenty of oil to the work, as this win prevent scratching or tearing the
cherry while being formed. It is well to make two of these holes, one at
each end of the piece of steel, roughing the blank with the first, which is
a little larger than the one used to finish the cherry of the exact size.
When this tool gets dull grind on the upper or cutting edge, but not too
much, as it will enlarge the hole, and the result will be to make a larger
cherry.

To form these blanks into cutting tools, a copy can be taken from the
cherries as sold to the trade.
Bear in mind to leave the grooves deep enough to receive the metal cut from
the blank mould when in operation.
It will be observed that the cherries as purchased (Fig. 69) do not have
their cutting ends terminate in that portion of the mould, but usually on
one side. This is done to insure a perfectly spherical form by having a
cutting side operating at the bot- tom of the hole while it is being formed.
It is somewhat difficult to make this form of cutting edge, and some
patience and care must be exercised or the blank may be spoiled.