I stretched the thinnest guitar string (.008) I could find across two posts on a piece of smooth board and cut mine.  It was an arbitrary height of .180 and it works fine to hold the powder from spilling out of the short 1.3 inch case and my 32-40 case.  Both breech seated

For my 40-65 I made up another board with guitar wire and cut the wad almost a half inch thick to take up powder space with my 4759 load.  It shot very well out to 600 yards with 9 hits out of twelve shots, 36, 24 and 12 inch gongs.  I missed the 12 inch gong three times out of 4.  With iron sights that 12 inch gong looks like a pin head thru the front aperture.

I left some of these loaded after a gong match for about 3 months and the accuracy went away.  The wad in contact with the powder may have been the reason.

I use the fine foam in my borschardt, cut with a serrated bread knife that came with an adjustable spacer for cutting the slices different thicknesses, bought it at the dollar store. I cut 1/4" slices then just press the sheet over the powder filled shell. Shoots the same as no wad, except I don't accidently dump powder into the chamber.           ...MIKE...

I agree with Mike and Jack !!!  Cut the foam into a 1/2" cube and shave off 1/16" to press/fit trim into the case mouth and seat with a dowel...   

Painless !!!    

I would leave it in the mouth only.
We have had one shooter put a ring in his RKS stainless steel barrel from putting the floral foam down on the powder.

MikeT wrote on Apr 15^th, 2013 at 8:52pm:


Spot on!