Casting with a PID Controller

[TexasMac]

I just posted a new article titled, Casting with a PID Controller. If you’re interested go to the following link:

http://www.texas-mac.com/Casting_with_a_...oller.html

From now on it will definitely be a part of my casting process.

Wayne

[Martini2]

Today was casting day and my pot is set up with a PID controller that I assembled from parts purchased at Amazon. Note the Lee pot controller is bi-passed in this case (connect existing wires inside Lee box). So now using the PID is only way with this pot. I did wire controller to correctly rated Duplex electrical outlet in separate box. This allows plugging different units in at separate times to use controller/thermocouple with those. The descriptive article shows and discusses the details and I concur. In my case the PID controller turned the less expensive Lee 20# pot into a viable ladle casting outfit. The plus side is you can extract higher controlled melt temperatures using the PID. Lee melting pots are controlled by a Bi Metal temperature switch that is remote from the melt. The PID reads direct with thermocouple in melt. So when fresh alloy is added to pot or sprews you can watch the temperature recover to casting level. With this method the melt temp does not run over causing a wait in production. Recovery in faster due to the electronic controllers. BTW I was running two 530 gr. 45 cal. molds so adding alloy came about often.
Aside having the PID controlling an outlet box allows setting up a small French fry cooking appliance to melt but not burn my Bees Wax boolet lube mixtures. This does preclude sharing cooking utensils with the kitchen staff. However the boolet lube turns out just fine out in the garage.

[TexasMac]

Martini2,

I would think bypassing the Lee controller is not a good idea. Consider what would happen if, while the pot is heating up, you get distracted or forget to insert the thermocouple for some reason once the lead liquefies. Full power will be supplied to the heater regardless of the alloy temp. Of course, if you leave the thermocouple in the pot once the lead hardens it’s less of a concern. But I use the same thermocouple for more than one pot so I pull it out of the alloy after the casting session. I’m curious, why did you bypass the lee controller rather than just turning it up all the way?

Wayne

[Martini2]

Your cautioning is correct. Probably should have included a disclaimer while offering PID and electrical info. Should have mentioned that my set up included separate thermocouples attached to the different units.
I had to go to industrial supply company and open an account to purchase the required type J thermocouple plugs and wiring. With past career in Glass industry, building and setting up furnaces and kilns it was no big thing. However you are most welcome to point out caution and it's noted to apply here. That said we also should note the info passed to this forum regarding use of technology (PID) was addressed to other forum members who may also use firearms and reloading equipment. So risk management an attention to details by said group should be intrinsic to the nature of all such activities and persons.

[Don McDowell]

Have heard a lot of glowing stuff about those PID's, but I can't help but wonder how we ever managed to cast good bullets with nothing but a cast iron pot over a fire of some sort and a ladle to work with.

[Nuclearcricket]

Excellent point Don, when you think abut it, it does make you wonder. Have we become that anal about things or was it back then, the things you didn't know didn't hurt you and didn't bother you?
Is food for thought.
Sam

[Don McDowell]

Don't misunderstand, this stuff is all pretty interesting and the like, but I do wonder sometimes how we goterdone without all the stuff we think we have to have now.

[Kurt]

Sam, Don.
My thoughts exactly. It's not just casting bullets but loading the round. As well as the lube used.
Casting the bullets is the least sensitive and easiest part putting these shells together. Turn your pot on or start the turkey cooker what ever you have on hand and start casting and when the wrinkles are gone turn the temp down if you see frosting starting. Frosting is an indication the pot is getting the alloy to hot.
When I cast and the bullets are filled out I turn the pot back till the light goes off and leave it there through the whole casting session. My Lee pot does not have a amber light like the Waage had so when the mould is throwing a good bullet I turn the heat back till I hear the click of the thermostat disconnecting. I never used a regulated pot. heck I used to use a plumbing LP fired furnace and a 30# cast iron pot and those bullets shot just fine. Didn't like the furnace because it was to loud and I had to do it outside in the heat of the summer and cold of the winter.
Work more on the casting procedures then how to regulate the alloy with in 5 degrees.
Kurt

[TexasMac]

Don't misunderstand, this stuff is all pretty interesting and the like, but I do wonder sometimes how we goterdone without all the stuff we think we have to have now.

They also rode wagons across country; road buggies, horses or walked to town and back, etc., etc., etc... Most of the "stuff" we use these days is not an absolute necessity. I enjoy taking advantage of new technologies if it's affordable.

Wayne

[rdnck]

Newer gadgets and techniques are usually quicker and easier, but I don't believe they are always better. A case in point is the thermostatically equipped electric pot versus the propane heated fish cooker and cast iron pot. The reason I say this is that the thermostat cycles on and off to maintain an even temperature and the temperature of the melt has to drop several degrees to cause the thermostat to re engage the power. This means the melt is constantly changing temperature up and down with an electric pot.

A propane burner on a fish cooker is equipped with a regulator, and once adjusted, the regulator feeds a constant, consistent and unchanging amount of fuel to the flame as long as your propane supply doesn't run out. The temperature on a pot of lead melted by a fish cooker simply does not vary, unless the amount of lead in the pot gets excessively low. With a 65 pound capacity pot and a 300 gallon propane tank, I keep both my lead and fuel supply in order. I feel that the propane fired heat source gives the most consistent casting temperature, but the drawback is that in hot weather, casting can really get to be an exercise in endurance and character building. Shoot straight, rdnck.