What went wrong with the balls?

[Smokey]

Dear wise ones.
Please suggest some possible causes so I can begin to trouble shoot this issue.
Lee .530 double cavity mold.

I made a batch of balls that are getting stuck at the muzzle. None of them will load. 
I measured a couple with calipers and compared them against some Hornady balls.  No difference.
Also, I tried a thinner patch. No go. 

The previous batch of balls from the same mold was fine. I don't get it.
What am I missing? What are some possible causes?

[Ohio Joe]

Dear wise ones.
Please suggest some possible causes so I can begin to trouble shoot this issue.
Lee .530 double cavity mold.

I made a batch of balls that are getting stuck at the muzzle. None of them will load. 
I measured a couple with calipers and compared them against some Hornady balls.  No difference.
Also, I tried a thinner patch. No go. 

The previous batch of balls from the same mold was fine. I don't get it.
What am I missing? What are some possible causes?

Are you using the same "exact" lead from the previous batch of balls / or did you add some lead that may not be 100% "soft" lead?

[Bigsmoke]

I agree with Joe.  It sounds like the lead is hard.  Wheel weights, perhaps?

[Hank in WV]

First thing I thought of also.

[rollingb]

Dear wise ones.
Please suggest some possible causes so I can begin to trouble shoot this issue.
Lee .530 double cavity mold.

I made a batch of balls that are getting stuck at the muzzle. None of them will load. 
I measured a couple with calipers and compared them against some Hornady balls.  No difference.
Also, I tried a thinner patch. No go. 

The previous batch of balls from the same mold was fine. I don't get it.
What am I missing? What are some possible causes?

Are you using the same "exact" lead from the previous batch of balls / or did you add some lead that may not be 100% "soft" lead?

Yep, sounds like you might have added some wheel weights to the mix. 

[Bigsmoke]

Do you have a scale that weighs in grains?  If so, weigh 10 Hornady balls, then weigh 10 of your cast balls.
Is it approximately the same?

[No Powder]

I have been following this thread and as usual, I'm confused. Smokey said he measured both the cast balls and the Hornady balls and found no difference. If that's the case, if the Hornady balls load allright, why wouldn't the cast balls be allright? I must have missed something.🤔

[rollingb]

I have been following this thread and as usual, I'm confused. Smokey said he measured both the cast balls and the Hornady balls and found no difference. If that's the case, if the Hornady balls load allright, why wouldn't the cast balls be allright? I must have missed something.🤔

It's easier to understand if you take a pure lead ball and "short start" it in the muzzle with an over-sized patch, then pull the patch and ball back out with a pair of pliers.

Now try the exact same thing with a HARD ball that is exactly the same size, it'll be much more difficult to "short start" the harder ball without driving it into the muzzle using a lot more force.

Also look at the pure lead ball after pulling it back out of the muzzle, and see how it was imprintd by the "weave of the patch material" and even possibly formed (just a bit) to the rifling's "lands".   

"Something has to give", when "starting" a patched projectile into the muzzle of a bore. 

The harder the ball is, the LESS "give" there is (all other things being equal). 

[No Powder]

Got ya !! Good explanation.

[Hank in WV]

The deforming of the ball on starting is called obturation.

[KDubs]

 I too have had issues with less than pure lead balls. 
 I cast .530 with a .015-.018 patch.  somewhere along the line, probably off a trade blanket, cant trust those English, I picked up some bad lead, WW I assume. 
 couldn't get those things to load without a mallet.  makes for nice shiny balls tho.  that mix is gone and i acquired 86 pounds of lead sheet from a friend who cleans out old houses. 
 Try the ball and patch removal advice, eye opening.
kevin

[No Powder]

Hey Hank, I thought obturation took place when the powder in the breech ignited, and deformed the base of the round ball as it began it's journey of departure. How many new things am I permitted to learn in one day? I may be over the limit already.

[waksupi]

Dear wise ones.
Please suggest some possible causes so I can begin to trouble shoot this issue.
Lee .530 double cavity mold.

I made a batch of balls that are getting stuck at the muzzle. None of them will load. 
I measured a couple with calipers and compared them against some Hornady balls.  No difference.
Also, I tried a thinner patch. No go. 

The previous batch of balls from the same mold was fine. I don't get it.
What am I missing? What are some possible causes?

Many .54 rifles prefer a .526 ball.

[Hank in WV]

Hey Hank, I thought obturation took place when the powder in the breech ignited, and deformed the base of the round ball as it began it's journey of departure. How many new things am I permitted to learn in one day? I may be over the limit already.

Oops, looks like you're right according to wiki

[Smokey]

I agree with Joe.  It sounds like the lead is hard.  Wheel weights, perhaps?

No. There are no wheel weights in the mix. Still might be that the lead is too hard. Threaded ball puller had a tough go digging into the ball.