We pour 20-40 tons a year in lead so i have seen a lot of things happen.Maybe 4 years ago when new lead was cheap we bought in lead pigs & melted the bars,very simple.Now with new lead at nearly 2 dollars a pound we buy scrap.Now your talkin lots of dangers & problems.
One post i seen somebody said have a fire extinguisher near by.Never ever spray a liquid on molten metal.It will blow up in your face.Either smother the fire with a steel top as i sometimes do or pour DRY sand on it & that usually ends the fires.
In our shop now i have old plumbers lead,roofing lead,pipes you name it & it all catches on fire or can go boom in a heart beat.We have a roof ventilation fan that draws out all smoke & fumes.i see some small stores that do this in their back rooms,crazy.
One problem using scrap lead is the consitancy or make up of the lead is always changing & that affects my employee's when they pour the lead into silicone molds.Most times you have to make adjustments to speed,pressure or heat.
One good thing about lead if you get hit by some it starts cooling as soon as it leaves the pot so burns are not that bad.We pour zinc & that stays 800 degree's for a while & it will burn you bad.Tin & Bismuth also not bad to deal with.
For do it molds most guys i know having troubles is the lead is not hot enough.Might need to be near 900 degree's.Also i hear a lot of smoking your mold.When we have problems we just dust molds with talc.Very simple helps the lead flow better but just turn the heat up.When we pour small 1/100oz or 1/64 oz jigs heat must be 930 degree's...
If you have questions on lead email us.There are a lot more things i can say.........
One question what do you use to core out worm sinkers to make the hole.i tried wire,nickeled wire,black nickel wire it all sticks.Teflon is best but i have none in the shop...........
Dave