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Actually going to try the seamless tube way and see if it works :ORLY: seems to be a few doing it that way, and I dont have access to any machinery at this time to make a mould

This is basically what was suggested
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Corbin uses a tube like I was thinking about - steel i think

To make lead wire, pure soft lead is first melted and poured into the billet...

1st batch would have enough heat in them - can return those billets to the melting pot

Maybe - but I'm sure they can be poured in straight pipe and fall/knock out easily = lot less work, esp when you need ~100 billets done
Big stack of tubes

Seen a vid around, but need to look...

Cant have any inclusion in them as that will fuck the extrusion die

They wanted a fortune to make the dies for the size I need and 500kg run.
I need different diameters and already have the tooling to extrude it
5x the price + tooling and 5x the amount is just not...

They want around $13 or so a kg... vs me making my own wire in exactly the sizes I need for around $2.50/kg

The slugs will be going into an extrusion die to make wire, and then processed further to make jacketed bullets - so do really need to be round
Seamless pipe would be ideal

The idea of alloy was...

I'm needing to make some ingots/billets of lead
Around 3/4" in diameter and 5" long
Was thinking on a piece of board with hole bored into it and standing some 3/4" ID alu pipe and pouring into that...