I put this together with information from various sources, the majority on-line, including some materials potentially suitable for fabricating non-toic shot and/or round balls:

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Shot material densities.
. . . . . . . g/cc . . % of Pb-Sn (average shot alloys)
- Sn . . . . 7.30 . . . 65% approximate - varies by source & allotrope mix
- Pewter 7.24-7.36 . 64-66% lead-free, Sn alloyed w/ Sb &/or Cu
- Pewter 7.38-8.65 . 66-77% lead-free, Sn alloyed w/ Sb &/or Cu &/or Bi &/or Ag
- Fe . . . . 7.86 . . . 70% "steel" - BHN 136
- Bi-Sn . . .9.69 . . . 86% "bismuth" currently 3% Sn - BHN 18
- ITX . . . . 10.0 . . . 89% ITX "Original 10" vs the 13g/cc turkey shot
. . . hardness claims obscure; malleability reportedly similar to hard lead alloys but abrasive per initial descriptions
- W-Fe . . .10.3 . . . 92% Federal "Tungsten-Iron" - BHN 270
- W-polymer 10.6 . . 94% Kent "Tungsten-Matrix"
- Pb-Sb-Sn (high alloy, bullet material ranging down into hard shot)
. . . . . 10.0-10.75 . . 89-96%
- W-Sn-Fe . .11.0 . . 99% "Nice Shot" (current density w/ Sn coating = 10.2/91%) - BHN 18
- Pb-Sn (average shot)
. . . . . 11.1-11.25 . nominal 100%
- Pb(pure) . 11.43 . 102% - BHN 5
- W-Ni-Fe . 12.0 . . 107% Remington "HeviShot" - BHN 266
- W-Cu-Sn . 12.0 . . 107% Olin "Tungsten-Bronze"

NOTE: Calculations of charge volumes need to take into account packing effects of different shot sizes and size of charge, e.g. Fe#1 = 63-67% Pb#6 per findings below, rather than the 70% of the bulk material densities.

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Steel shot contained in lead shot shotshell-reloader bushings calibrated for Pb#6:
bushing - Fe#1 +/- 1/16oz
1.1/2 - 15/16
1.5/8 - 1.1/16
1.3/4 - 1.1/8
1.7/8 - 1.3/16
2.1/4 - 1.1/2

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Bismuth shot contained in lead shot bushings (calibrated for Pb#6?):
bushing - Bi#4
1.3/8 - 1.3/16 (=86%Pb)

In one of my hunting partner's shot dipper 1.1/2Pb -> 1.1/4 Bi#4 as he measures (struck?) =83%Pb.

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This was as comprehensive and accurate as I could assemble at the time, but since I neglected to record my sources, it is worth exctly what you paid for it.

Regards,
Joel

Last edited by Joel.V; 09/26/13 05:00 PM.