By George E. Frost *A (11.201) 4410 A Publication of the National Rifle Association of America c in m ii MAKING w c ml U MAKING An insider's Story By George E. Frost A Publication of the National Rifle Association of America George E. Frost George Ernest Frost has been known as "Jack" to his friends in the ammunition industry for nearly six decades—since the day in 1935 when he went to work for the Western Cartridge Co. of East Alton, Illinois. A graduate of Iowa State University, with a Bachelor of Science degree in Chemical Engineering, Frost joined the Western staff to pursue a company sponsored project involving dynamite filler, and stayed for a 27-year career that saw him fill managerial and executive positions in the sales, product services, quality control and military liaison divisions of Western and its parent company, Olin-Mathieson Chemical Corp. While a part of the Olin team. Frost gained a reputation as a top-notch, competitive rifleman and shotgunner, and an avid hunter and outdoorsman. In 1962, he moved to Lewiston, Idaho, to become Vice President for Production of Cascade Cartridge Co., where he established ammunition manufacturing facilities in Lewiston and a subsidiary plant in San Luis Potosi, Mexico. From Mexico, Frost moved to the Republic of the Philippines and to the position of Executive Vice President and General Manager for The Squires-Bingham Manufacturing Co. He was instru- mental in the establishment of facilities for the production of both military and sporting metallic cartridges and shotshells. Retired since 1979, Frost continues to work with Squires Bingham's successor. Arms Corporation of the Philippines (ARMSCOR), as a consultant. His most recent undertaking has been the establishment of production of .22 rimfire match ammunition for sale throughout Asia and the Pacific rim. DEDICATION To the host of friends in the ammu- nition business who in one way or another helped in my education. BOOK SERVICE Copyright © 1990 by the National Rifle Association of America All rights reserved including the right to reproduce this book or portions thereof. For information, address the National Rifle Association, 1600 Rhode Island Avenue, N.W., Washington, D.C. 20036 ISBN 0-935998-57-8 Library of Congress Catalog Card Number 90-053200 Published May, 1990 Printed in the United States Cover Design by Michael R. Bloom Published by the National Rifle Association of America 1600 Rhode Island Avenue, N.W. Washington, D.C. 20036 George Martin, Executive Director, NRA Publications Frank A. Engelhard t, Dep. Director & Book Service Manager Joseph B. Roberts, Jr., Editor, NRA Book Service Michael A. Fay, Manufacturing Director Harry L. Jaecks, Art Director CAUTION: All technical data in this publication, especially for handloading, reflect the limited experience of individuals using specific tools, products, equipment and components under specific conditions and circumstances not necessarily reported in the article, and over which the National Rifle Association of America (NRA) has no control. The data have not otherwise been tested or verified by the NRA. The NRA, its agents, officers, and employees accept no responsibility for the results obtained by persons using such data and disclaim all liability for any consequential injuries or damages. TABLE OF CONTENTS ACKNOWLEDGEMENTS ix Burst Heads Dropped and Blown Primers INTRODUCTION xi Pierced Primers Accuracy Problems CHAPTER I FIRST IMPRESSIONS 1 Blowback CHAPTER II THE CARTRIDGE CASE 3 Hangfires Why Brass? Poor Patterns Rimfire Cases Case Problems Centerfire Cases Bullet Failures Oil CHAPTER III THE BULLET 25 Some Background Self-loading Shotguns Lead Bullets Bullets in Barrels Jacketed Bullets Damaged Guns Lead Shot CHAPTER XI ACCURACY 123 Iron Bullets Interior and Exit Effects CHAPTER IV SHOTSHELLS 37 In-flight Effects Cases Control of Accuracy Wads CHAPTER XII THE .22 MATCH 131 CHAPTER V CLAY TARGETS 45 CARTRIDGE Development CHAPTER VI PRIMERS AND PRIMING 47 Manufacture Chemicals and Chemistry The Case Primer Mixes The Bullet Cups and Anvils Loading Assembly Quality Control Packaging Quality CHAPTER XIII QUALITY CONTROL 139 Commercial Ammunition VII CHAPTER POWDER 71 Military Ammunition VIII CHAPTER LOADING 79 CHAPTER XIV FIRES AND EXPLOSIONS 145 Machines and Methods Recent Developments CHAPTER XV WORKING IN FOREIGN 149 Shotshell Loading LANDS Mexico CHAPTER IX BALLISTICS IN THE 89 The Philippines FACTORY Velocity Testing CHAPTER XVI TIDYING UP 155 Pressure Testing Acids Standards Lead Styphnate Accuracy Tetracene Bullet Pull Barium Bullet Upset Residue in Sumps Patterns Color Primer Sensitivity Metallic Ions Function Testing Cyanide Powder Evaluation Detergents Moisture and Volatiles CHAPTER XVII A FEW FINAL THOUGHTS 159 Other Tests CHAPTER X TROUBLES 107 Misfires Squibs ACKNOWLEDGEMENTS pecial thanks to: Dimitrio "Bolo" Tuason, pres- S ident of Squires Bingham-Armscor who en- couraged me to write this book, which started as a text for the company, but grew; to the late "Bo" Bohannan who read the manuscript with a critical eye; to Joan Ferrar who had the chore of reducing my hand writing and tapes to the typewritten page; and to Ely Descalso, whose drawings are much more artistic than mine. INTRODUCTION he groundwork for this book started over half from both sides of the fence - both makers and frown on the T a century ago, when I joined the Western users. Today's large corporations Cartridge Company as a chemical engineer fresh non-conformist, but in smaller companies, which out of college, with one unique qualification - I Western Cartridge once was, the key people who was an expert in grinding chicken feathers. got things done, who sold the product, and kept personalities. In the Since that time I have been intimately involved it sold, were strong colorful I've there was a in all phases of ammunition manufacture as well small companies where worked, as in engineering, development, sales and service, company personality, a warmth of fellowship, with some powder making experience as well. My pride in product, and a pervading democracy that work has been in three companies and five plants, made working and social life a pleasure. Foremen, in Illinois, Connecticut, Idaho, Mexico and the executives, and workmen all shot the product they Philippines. None of the five has been much like made, and knew firsthand how it should be. Some any of the others, except for the basics. of these people are named, in the pages to follow, It's been a busy 55 years, but I've still had time as a small tribute to their help and knowledge. for maybe more than my share of shooting com- Over the many years that I went to the Grand petition and hunting, with a good bit of travel American Trap Shoot and to Camp Perry (National thrown in. There have usually been adequate Rifle Matches) I shot at a great many matches, quantities of ammunition to shoot- call it "testing," brought the word to jobbers' sales meetings, sat - as one of the perks of the job. in hunting camps, dropped into sporting goods shoot- So I guess, all in all, and particularly if one has stores, and otherwise met with hunters and an interest in guns and ammunition, which so ers. I met a great many grand people and only a many do, it's been the sort of job gun and am- very, very few whom I didn't care to know. Our munition nuts dream about. commonality of interest made conversations easy Not that there haven't been occasional harsh and I learned a lot by listening. moments, some troubled times, five years of war, Most shooters have an intense urge to pass on the wrenches of pulling up stakes, saying good- their experience to others. The man from the factory bye to friends and familiar haunts; and trying is apt to be somewhat of a social lion if he's a good periods of settling down in a new community. It listener. At the same time, his pronouncements has been easier for me than for the family, as I had are usually accepted as being fairly close to the a continuity of interest in my work. ultimate truth. Partially this is true because he's The changes in location have been broadening, away from home and, therefore, something of a even within the United States. No matter how you prophet. More important is the fact that he's been slice it, industrial Illinois isn't quite the same as closer to where it's happening, in the factory. resort and farming Iowa, where I grew up. Con- The question was asked me many times, and necticut surely isn't much like the Midwest. Idaho I'm sure it has been asked of most all ammunition is mountains, lakes, forests, and streams, with "factory men," "Where do I go to learn how to potatoes and wheat, all Western style. Mexico was make ammunition?". Young, excited engineers a whole new ball game with a second language want to get into the business, but would like to thrown in. The Philippines, where I now am, is approach one of the ammunition companies with worlds, or more properly an ocean, apart from the more basic knowledge of the subject than can be U.S. and Mexico, with a daily dose of three lan- gotten from the reloading manuals and magazine guages and a vastly different set of mores and articles. customs to deal with. The variety has always made The answer isn't, "Go read a book," because the job more interesting and more than a little there aren't any complete works on the subject, at challenging. least none recently. It's not that ammunition mak- Somehow this business has seemed to bring a ers aren't literate - there are many who can read great many attractive, interesting people together and write - but commercial ammunition making xi AMMUNITION MAKING has been a small field with only a few companies Still, there was a loud insistent demand for in operation at any one time.