A scrap dealer is the best source for cheap lead. Go for scrap lead sheeting if possible. It's easier to cut into small pieces for melting.
Scrap lead piping is usually cheaper but can contain water, which is very dangerous when melting lead: the water can become super-heated steam and explode propelling molten lead.........well you can get the drift of what could happen.
I would agree with IDPearl and steer well clear of car batteries. You are dealing with a very corrosive acid as well as moisture and the lead yield is low. Definitely not worth the risk or the effort.
Never melt lead indoors in the home. Lead fumes are a harmful substance with known toxicity. Kids are especially susceptible to lead toxicity so any residues in your kitchen after melting could be harmful.
I use a small gas stove in a very well-ventilated place, either outside when there is no risk of rain or drizzle (remember note above about water and molten lead). In poor weather, I melt lead in the garage with all the doors and windows open and making sure there is a good cross-flow of air that ensures that the lead fumes are carried away from the breathing zone. Using a lid on the melting pot reduces escape of lead fumes. Keep an eye on the flame though, to make sure it does not go out if the draught is too strong.
Always wear heavy gloves or gauntlets and make sure your arms are covered. I use a pair of safety glasses that I picked up fairly cheaply in a DIY store. If you can't get your hands on a suitable mask that will protect against lead fumes, then you should make sure that you are reduce exposure to the lead fumes (see above about cross flow and breathing zone etc.)
A crucible for melting lead a goodoption. Best of all is a small custom, electrically powered lead melting crucible. If you are using a pot for melting lead, go for a heavy iron or steel pot with a lid and a bolted handle. Aluminium pots are not up to the job of coping with the high temperatures used in melting lead. Welded handles that appear to be on a lot of pots and saucepans on the market are not advised. The combination of high heat and weight of lead can see these type of handles failing with disastrous results
Check flea markets and charity stores for old heavy iron pots or saucepans.
Again, make sure everything you use is
absolutely dry
If you really are serious about making a large number of weights and have a few angling mates want to chip in with you, a Lee lead melter would be a good (and safer) investment. See link below for an example:
http://www.thegunshop.co.uk/reloaders-s ... elters.htm
I know that the above sounds very cautious but once you get into the routine of working safely with lead it will become second nature and not a hassle at all. I've been making my own lead weights for a few years now without any trouble.
Last edited by Esox lunatic on Mon Apr 03, 2006 8:49 pm, edited 3 times in total.