What is it's maximum thickness?

Carbon arc rod in a stinger. No air.  Never tried it myself but have been told it works. Rent an air compressor and jack hammer with spade bit. Use ear plugs.

   

    Joe.

Boats, if that block of lead was in my backyard, here's what I would do:
* Jack up a side of the block with a hydraulic jack
* Cut long section spaces to preclude the heat sink issue with the sawzall starting on the bottom  
* Buy aluminum gutter pieces (the widest you can purchase) the length of the block
* Buy this torch and many propane tanks, you'll need them  ...  might want to ask a gas dealer to rent one of the big propane tanks
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The 3000 degree torch does an quick excellent job melting scrap lead I get at the scrap yards
* Melt the cut sections into the gutters
* Then sawzall the smaller blocks from the gutter and start stacking them up  
Hmmm - 5000 lbs is approximately 175,000 bullets weighing 200 grs!  Happy casting or selling!

An old time shooter friend used to tell a story of asking a friend who had a large chunk if he would sell some. The guy picked up his chainsaw, turned his head sideways and began to sling little lead particles all over the place. I guess it worked quite well except for all the blood. 

Jack

QuestionableMaynard8130 wrote on Sep 30^th, 2013 at 4:36pm:

AND be on the look out for those pecky lead eatting California Condors. I think they would get there before you get 1/4 the way done. They can smell that hot lead for 3000 mi's you know.

Frank

I like the chainsaw idea. I don't like the carbon arc idea; I don't think you'd survive that for very long. Jackhammer would work if you have a big young guy to run it.
  Thanks boats, this the most interesting topic we've had in a while.

boats, Louis is remembering my experience with large chunks of Lead. I got advice here from a Boat yard  guy on use of a chain saw. Worked the beans! It takes two guys, one on the saw and one to one side with a squirter with kerosene squirting the Kero on the bar/chain. The Saw guy needs to stand off to one side as the Lead chips coming off the Saw are like .38 Special slugs and hurt! Also position a plastic tarp to catch the chips as there will be lots. The chain should be freshly filed, it does no noticable damage to the chain. And it does go like butter. I brought home 7,300 Lbs from Virginia and could have had more if I wanted it. So far have only used 600 lbs in 25/1 lead tin Alloy. Hope to live long enough to use up all the rest. HTH Regards, FITZ. P.S. The chips come off the bottom just like wood chips But with more energy, they tend to hit right about mid chin bone. Does not take long to wise up and get out of the way. FITZ.