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R.H. VanDenburg, Jr.In the study of shotshells, perhaps the least understood segment of this most interestingsubject is that of the all-metalshell. While our modern plastictubed shells were preceded bypaper-tubed shells, it is not true thatall-metal or brass shells precededthose with paper tubes. Early on inthe development of breech-loadingarms, self-contained ammunitionwas bound in paper or linen. Inshotguns, the earliest shell that themodern shooter would instantlyrecognize had a brass head, a papertubed body and an external primer.RELOADINGBrassAt the same time – the latter half of the nineteenthcentury – well-traveled sportsmen were taking tothe field with 12, 10, 8 and even larger bore riflesthat used brass shells. These self-contained shellswere sturdy, easily transported and waterproof.“Why?” asked many a waterfowling hunter, “can’twe have a brass shell, too?” Waterfowlers, to agreater extent than most others, felt the need for awaterproof shell. Actually, the paper shells of theday were intentionally moisture-resistant to varyingdegrees. The absorption of moisture into the shellwas a very real concern, as it could dilute the effectiveness of the black powder, and the paper shellscould swell to the extent they could not be chambered. Still, the waterfowlers had a point and whilemanufacturers continued to develop more moisture-resistant paper shells, attention was turned tothe development of all-metal shells as well.There are components galorefor loading brass shells with eitherblack or smokeless powder.The earliest attempts simply substituted drawnbrass tubes for the paper tubes, affixed them to thebrass heads and turned them in to secure the overshot wads. Wax or shellac was typically used to waterproof the shell mouth. Drawn, one-piece shellsfollowed as did the use of other metals such aszinc, aluminum and to a lesser extent steel. Oneparticularly interesting attempt employed a thinpaper shell with a zinc liner actually longer than thepaper. The zinc liner was then crimped in a pie orstar crimp that we would recognize today. All theseshells, however interesting and effective, had their48www.handloadermagazine.comHandloader 266

PART I: Practical Tips for VersatilityShotshellsThis Model 1897 Bakerexternal hammer gun isfairly typical of its ilk.June-July 2010www.handloadermagazine.com49

RELOADINGBrass Shotshellsdrawbacks. The brass shells hada larger interior capacity thanpaper shells and required largerwads. True pie-crimping couldonly be accomplished by the ammunition factories, and the everincreasing cost of metals wouldeventually make the price prohibitive.The concept of the all-brassshell attracted the attention inEngland of Dr. Charles J. Heath,at one time president of theBritish Waterfowlers’ Association. Dr. Heath developed twoprecepts of shotgunning sciencethat, in differing forms, are stillwith us today. One was a “chamberless gun” that might bethought of as an early attempt atbackboring. Dr. Heath reasonedthat with the thin brass tubeshotshell there was no need forthe heavy forcing cone requiredof a gun shooting the papershells of the day and that it couldbe essentially removed and thebore enlarged to much the samesize as the interior of the brassshell. Of course, such a shellwould require much larger wadsand, for waterfowlers, hold moreHistoricalinformationregardingbrass shotshells isfound in avariety ofolder booksand catalogs.powder and shot. At the sametime such loads would not besuitable, perhaps even unsafe, foruse in a gun of standard dimensions. Few chamberless guns, asDr. Heath envisioned, were everbuilt.The second development of Dr.Heath was what today we thinkof as the “high density-low velocity” principle in which more andlarger shot were paired with alower-than-normal velocity for avery effective and useful load.In the 12-gauge, 2 1 2-inch brassOld published reports highlighted all-metal shells, this one from areprint of the “ALCAN Shotshell Reloader’s Manual, No. X” in the firstHandloader’s Digest.shells, Dr. Heath was able to pushas much as 2 ounces of BBs at800 fps with what he claimed tobe astonishing results.All the above, admittedly askimming of the highlights of theera, took place in England andEurope. In the U.S. similar activities flourished but with a decidedly American flavor.In the 1878 E. Remington & Sonscatalog of breechloading rifles,shotguns, pistols and ammunition, the company had this to say:“Of late years, the reloadingbrass shells for shotguns havecome much into use, and we recommend every sportsman tohave some of them on hand, asthey can always be loaded inplaces where it might be difficultto obtain paper shells. They arealso better at taking a larger wadin the same size chamber, andgiving more penetration, and areless liable to injury by wet. . . .We are prepared to furnish metalshells that we know are suitablefor our guns. They are made witha solid head, or flange, and fittedwith a steel cone, upon which theprimer is placed, and explodedby the firing-pin of the gun.These shells are put up in boxescontaining twenty-four shells,with primer extractor . . . for reHandloader 266

VICKERMANInline Seating DieGMW, Inc.Tel: 509-382-4159www.gmwvickerman.comQuality hand-cast bullets for reloaders,competitors & recreational shooters!Extensive selection of pistol, rifle,big bore & paper-patched bullets.Website: www.MontanaBulletWorks.com7730 Hesper Rd. Billings, MT 59106 Tel: 406-655-8163High PlainsAbove left, the CBC shell is drawn brass and accepts a large pistolprimer. Right, the RMC shell is turned from solid brass and cut for a209 battery cup primer.moving exploded caps; also inboxes containing ten shells, without extractor.”In comparing the above, in England and western Europe, shotshells were typically purchasedfrom an ammunition manufacturer or from one’s gunmaker. Inthe latter instance, the gunmakerpurchased empty shells, paper ormetal, and loaded them for hiscustomers, often to the customers’ specifications. In the lesssettled America, the need to beable to load, or reload, one’s ownshells far from any settlementwas of paramount concern.Fifty years later, in 1928, Maj.The RCBS Cowboy Shotshell Die setis designed to handle the CBC shells.Reboring & Barrels, L.L.C.Charles Askins, in his ModernShotguns and Loads, was ratherdismissive of both chamberlessguns and brass shells: “Whateverthe chamberless gun may or maynot do in the way of patterns, it isnot a practical arm. We are notgoing back to black powder norto brass cases, which must behand-loaded and carefully handled as was true fifty years ago.”In spite of such feelings, whichwere no doubt shared by many,the all-metal shell held on. In thefirst annual edition of Handloader’s Digest, edited by John T.Amber of Gun Digest fame andpublished in 1962, are depictedtools for loading brass shells. TheOffering Button andCut-Rifled Barrels.Most calibers and twist rates.Contact: Norman JohnsonPhone: 701-448-9188E-Mail: nrjonsn@westriv.com243 14th Avenue NW - Turtle Lake, ND 58575King Shooters Supply Inc.Roger’sBetter BulletsIF AT FIRST YOU DON’T SUCCEED. . . RELOAD 124 W. Church RoadKing of Prussia, PA 19406(610) 491-9901www.kingshooters.comHours:Tues - Fri: Noon to 9 p.m.Saturday: 9 a.m. to 5 p.m.FirearmsBuy Sell TradeClass 3 DealerBulletsRoger’s Better BulletsZero Frontier SierraHornady WinchesterReloadingJune-July 2010www.handloadermagazine.com51

RELOADINGBrass Shotshellsbook also contains the “ALCANShotshell Reloader’s Manual, No.X.” In it are several pages devoted to all-metal shells and thereloading of them. These includethe Alcan-Metal shotshell, whichwas a four-piece shell: a steelhead, aluminum tube, basewadand a metal overlay cup thatserved to reinforce the tube inthe powder area. Also listedwere a solid brass shell for usewith smokeless powder withRemington-type 57 primers and aBerdan-type solid shell for usewith black or smokeless powderand Berdan primers. Each wasavailable in gauges from 10 to.410, including 24 and 32 gauge.All-Metal shotshell reloading kitswere available in 12 gauge. In thebook’s section on Remingtoncomponents were listed all-brassThe C-H tool is a two-die set with a full-length sizing die and a seating/crimping die.shotshells in 12, 16, 20 and 28gauges and .410 bore. All but the.410 used No. 2 1 2 large pistolprimers. The .410 used No. 1 1 2small pistol primers. Our militaryused these in 12 gauge as guardshells with buckshot. Winchesterprovided a similar product.Tired of Run Out?Tired of Over Sizing?Want to ExtendBrass Life?The WTC Sizing Dieis the Answer to yourSizing Headaches!Minimal brass sizing for flawless chambering and maximum case life.Concentricities of .0005" or better from topto bottom.Head space adjustment within the die viahardened and ground tool steel retainerrings.Standard die body will accept die inserts forany caliber from 6mm to 30-06.Now introducing the Magnum die body thatwill accept larger cartridges up to 416 Rigby.2 part die insert construction - one for thebody, one for the neck and shoulder.Every die is custom made based on your fireformed brass.Wildcat Development and hydraulic formingservices available.201 Old Homestead Hwy. * N. Swanzey, NH * 03431603.352.9521 * Warner-tool.com52www.handloadermagazine.comAll well and good, you say, butsurely this is still the dim past.Not quite. Today there are atleast two sources of brass shotshells for U.S. reloaders and twosets of reloading dies. There alsoare components galore for loading brass shells with either blackor smokeless powder.The first all-brass shotshells areheadstamped “CBC (and thegauge)” and are manufactured byCompanhia Brazileira De Cartuchos in Brazil and imported intothe U.S. by MAGTECH Ammunition Co., Inc. of Minnesota (1800-466-7191). They are availablein 12, 16, 20 and 28 gauges and.410 bore. Other sizes are manufactured but may not be availablehere. These are drawn brass,one-piece shells with the primerpockets protruding into the shellinterior. Shell length is nominally21 2 inches. The 12-gauge shells onhand measure from 2.440 to 2.465inches. In type, they are very similar to the thin brass shells of Dr.Heath’s time and the Remingtonshells manufactured into the midtwentieth century. The primerpockets are, or were, sized forthe 6.45mm (#56 Tupan) primer.In the early years of their availability, we were informed to usesmall pistol primers. At sometime this changed, at least forthose shells imported into theU.S. Current CBC shells take aHandloader 266