BPCR Reloading – An Innovative Approach
Summer 2007
Note – The following was published in the summer 2000 edition of the Black Powder Cartridge Rifle News. The original photos were black & white. The ones displayed below were taken later in 2007.
First, a word of caution, if you consider yourself a “traditionalist” in the reloading of black powder cartridge rifle (BPCR) ammo you should skip the following article as it will insult your sense of tradition. Or if you enjoy hand reloading with manual equipment, and you’re convinced it gives you an advantage, then you, too, can skip this article. Although I applaud those who employ time-honored reloading equipment and techniques, competitive pressures make it hard to ignore the advantages brought on by recent technology advancements. I know most of you use a “modern” balance beam scale and press. And to remove some of the drudgery in the process, many have shelled out good money to own one of the new digital scales. If so, then you should have no problem taking the next step. I’d like to share with you a system I’ve improvised, using modern technology, to improve the BPCR reloading process.
I enjoy most aspects of reloading, almost as much as the shooting and competition. It’s an opportunity for experimenting, improving reloading formulas, and refining old techniques. But, as you well know, some of the steps are very time consuming and tedious. I never looked forward to dispensing and measuring the powder by hand, and trickling the powder by hand into the drop tube. I had recently purchased a RCBS Powder Pro™ Digital Scale, which was a major improvement on the measuring process. With the addition of RCBS’ Powder Master™ Electronic Powder Dispenser, I saw a way to automate the step of trickling powder into the drop tube. Early on I’d realized that one key to good reloads is uniform powder compaction, determined by how evenly the powder is trickled. I was never successful in maintaining a consistent rate and was always on the lookout for a better method. Using both RCBS units together I planned on taking advantage of the precision dispensing and measuring technology to streamline, automate, and gain precise control over the process.
The Powder Pro™ and Powder Master™ are designed to automatically and effortlessly work together to measure out exact amounts of smokeless powder. An infrared data port provides the communication link. The powder dispenser is programmable to dispense up to 99.9 grains with an accuracy of ±0.1 grain. The powder is trickled out at a constant and repeatable rate. The scale measures the powder weight and informs the dispenser when to stop. I intended to construct a system to take advantage of these key features for BPCR reloading, a task the units were not designed for.
Picture the powder dispenser setting on top of a tall stand that supports a drop tube. The dispenser is trickling black powder into the top funnel of the drop tube. The scale is located at the bottom of the stand under the drop tube and has a primed cartridge case setting on the scale platen. The case is centered under the drop tube. Once the correct powder charge is dropped, the dispenser automatically stops. The concept was simple, but there were a few obstacles to overcome. The main one was figuring out a way to separate the units while maintaining the communication link.
The units are designed to work close together on the same flat surface, close enough for the powder dispenser to drop a charge directly into a pan setting on the scale platen. Therefore, the infrared transmitter in the scale, and the receiver in the powder dispenser are designed for close proximity and alignment; certainly not as I intended to use them, with the dispenser located almost three feet above the scale. Looking for a simpler solution than opening the units and redesigning the data port, which would also void the warranty, I decided to use fiber optics to maintain the communication link. Infrared light is not visible light, but it will transmit through fiber optics. An appropriate length of fiber optic cable and jacks cost me $30 at a local electronics store. This approach required only a minor, exterior modification to each unit. By simply unplugging the cable, both units will function as originally designed.
To hold the drop tube and properly position the dispenser and scale, I constructed a lightweight, very stable, and inexpensive stand out of plywood and zinc-coated threaded rods. The threaded rods provided a method to tie the plywood shelves together into a rigid framework, which also allows easy adjustments for different length drop tubes and cartridge cases.
The final obstacle was caused by the extreme sensitivity of the scale. It’s so sensitive that the drop tube must not touch the cartridge case setting on the platen. Even the slightest contact upsets the scale accuracy. Since most drop tubes are only slightly smaller in diameter then the cartridge case, it’s almost impossible to align them sufficiently, without touching, to capture all the powder. It’s analogous to aiming a water hose at another of similar diameter, without connecting them, and expecting all the water to enter the second hose. I made a very small lightweight funnel from thin sheet brass (shim stock) to set on top of the case. This added a minor step to the process but guarantees that all the powder is “funneled” into the case, even if the case is not aligned exactly under the drop tube.
Once both units are properly aligned, calibrated, and programmed, it’s only a matter of placing a cartridge case on the scale platen and pressing a couple of buttons to zero out the case & funnel weight and drop the desired charge. The exact amount of powder is trickle-dropped into each case resulting in uniform and identical powder compaction from case to case. The system is easy to setup, works perfectly every time, and is an absolute joy to use. It takes less than a minute to dispense the 63 grains of FFg powder I use in .40-65 ammo. To change the charge weight, just program in the new amount to a tenth of a grain, press the enter button, and you’re ready to fill more cases. This setup is perfect for experimenters, a category that all reloaders, especially BPCR reloaders, fall into. But I have to warn you that your old manual powder dispenser and balance beam scale will be relegated to the back shelf of your reloading bench to collect dust, never to be used again.
A final caution, since the manufacturer obviously did not envision the Powder Master™ being used with black powder, the housing is plastic and features a plastic powder hopper. RCBS’ literature says the powder hopper is constructed of anti-static material, but RCBS does not recommend its use with black powder. To play it safe, several modifications can be made to eliminate the possibility of static discharge. You could construct a replacement hopper from thick brass shim stock soldered together at the seam, or line the inside of the plastic hopper with very thin brass shim stock or aluminum foil. An additional precaution is to lightly spray the inside of the powder reservoir (where the dispensing tubes pick up the powder) with Static Guard® anti-static spray, available from most grocery and department stores. It dries quickly and does not affect the powder or the plastic housing. If you use another brand, I recommend you first test the spray on a small portion of the housing to see if it reacts with the plastic before drying. Perhaps, in the future, more manufacturers will come to the realization that BPCR shooting and reloading is a growing sport and ensure their equipment is safe to use with black powder.
The powder dispenser and scale are available from RCBS through your local reloading retail outlet, or directly from PACT, Inc., Grand Prairie, TX, (972) 641-0049. PACT designed and manufactures the units for RCBS. Another source is Midway USA, Columbia, MO, (800) 243-3220, which sells the units under both the RCBS and PACT brands. By the way, if anyone is interested in a balance beam scale, manual powder dispenser, and trickler, I know where you can find some good used ones.
Wishing you great shooting,
Wayne