MAKING CARTRIDGES

By Patrick Reardon

PART 2 - March 2005

Since my first essay on this subject I have attempted to refine and improve my techniques as well as to correct errors and omissions in the first article.

1.0 Errors & Omissions

I neglected to note one operation when rolling cartridge tubes of any calibre. Once the cartridge paper is rolled around the dowel, place the tip of the forefinger into the end of the tube resting on the nose of the dowel before you pull the choking cord tight. The presence of the finger forces the paper out into a consistent "flower" or "rosette". The cartridge can then be tied off as described earlier. Sketch K shows this.

My earlier description of constructing a .69cal ball cartridge was incorrect. In ignorance, I had assumed that the two strands of choking cord at the nose of the cartridge were twisted together and brought down as one strand to encircle the base of the ball. Now, having studied an original cartridge in the collection of The Museum of the Confederacy, it is clear that the two strands of choking cord are brought down individually on opposite sides of the ball (i.e, at 180 degrees to each other) to the base of the ball, each being secured by a half-hitch at that point, i.e. NOT tied together. When both cords are secured, cut off the excess fairly close to the knot. Sketch L below illustrates this.

2.00 Improvements

A. Undoubtedly the greatest improvement is entirely due to Mr. Jim Kanne of California, a fellow enthusiast. Jim recommended a paper which he reckoned was as close to the original in weight and colour as it was possible to get. To prove his point he had the great generosity to send me an original empty cartridge tube so that I could compare for myself. He was absolutely correct! The paper is decorator's masking paper made by 3M I believe and is available in the US in a variety of different roll widths (I now use 18"). Jim's paper demonstrated that my original paper was far too thick. I am now trying to source a similar paper in the UK. Of the earlier papers I recommended, I have retained the 90gsm brown Kraft paper to make powder cases as this thicker material imparts a degree of strength to the cartridge tube.

B. As an improvement to the manufacture of .69 ball and .69 buck & ball cartridges I have found a source for moulded pulp paper balls to simulate both the ball and the buckshot. These I found in an architectural model shop (see details below). The two sizes I use are 15mm for the ball and 8.5 mm for the buckshot. 15mm (.59") is not quite correct for the ball which should be approx. .625" in diameter. To increase the diameter I wrap the ball in paper tissue (Kleenex) as shown in sketch L. This process is virtually identical to the manner in which round balls were patched for use in muzzle-loading rifles.

The 8.5 mm balls (.334") are very slightly oversize for typical buckshot, but they will do. Sketch L illustrates this.

C. Using the pulp paper balls I have now made a reasonable facsimile of a buck & ball cartridge. The first step is to glue three 8.5 mm balls together in the form of a clover-leaf. When dry (overnight) glue them squarely to the nose of a paper tissue wrapped 15mm diameter ball. Insert the assembly into a cartridge tube, cut off the excess tissue, push home and follow with a powder case. Again, see Sketch L.

To tie the buck & ball cartridge, the process is identical to that described earlier for the simple ball cartridge but repeated, once at the base of the buckshot and once at the base of the ball. The tying process should be carried out with a powder case in place. Sketch M shows the process.

D. Having now had a fair bit of experience in cartridge manufacture I have found it better to glue the end of the powder case closed rather than to rely only on compression. If you refer to Sketch F in the first essay you will see the construction method recommended. Now I add a dab of glue under the flap then fold it flat by pressing it firmly against the work surface. Leave overnight to dry.

As I emphasised in the earlier article, frequent reference to "FROM ROUND BALL TO RIMFIRE" will provide the best guide to the appearance of all civil war period cartridges and packages.

Source for pulp paper balls:

Return to Article Index