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Enlarging bullet mould cavities can be done by lapping with succeedingly larger castings, but in my experience, there is a law of diminishing returns that says +0.001” is easy; +0.002” is doable, but laborious; +0.003” is at or beyond the outer limit of possibility. Trying for that much or more may eventually get you your desired dimension, but the bullet cavity will become noticeably oval across the casting line. A regular production mould is likely somewhat oval already, so this condition may or may not be bothersome to the end user, who sizes the bullets in a lubrisizer. Those who insist on zero runout may get more upset if their expensive custom mould is a half-thousandths fatter across the parting line at the end of a lapping session. Lapping ovalizes bullet cavities faster per thousandth diameter increase if the mould is held tightly in handles, but some runout will occur even if the blocks are fixtured in a four-jaw lathe chuck, and the excess lapping compound and swarf cleaned off the faces frequently. I usually put the bullet in a collet, drill and tap it with some appropriate-sized tap, and leave the tap in the lead as the shank. If I use an electric drill, it is a variable speed one, at very low rpm. Thirty seconds or a minute slow turning, open blocks and clean faces, the same time more in reverse, clean mould and cast a few to check diameter, and, if necessary, supply the next size laps. It is, of course, more involved with the four-jaw chuck, but the buildup must not be allowed.
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