Bullet Shell Valve Caps (all credit and a tip of the hat to Mrballeng).

Picture of Bullet Shell Valve Caps (all credit and a tip of the hat to Mrballeng).
 I was in my shed today and my eyes fell upon my stockpile of spent rifle cartridges. I recalled Mrballeng's instructable for using 40 cal. shells to make valve caps.
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Step 1: Select some shells.

Picture of Select some shells.
I have 40 cal. shells among others, and after a quick rummage through the pile, I  realised that they all looked similar in dimension around the base.

Step 2: A quick check with the vernier.

Picture of A quick check with the vernier.
A quick check with the vernier caliper confirmed my suspicions. As shown, the O.D. of these cases are: .270 WIN brass and plated - 11.9mm. .44-40 WIN - 11.8mm. .22-250 REM - 11.8mm. .243 WIN - 11.9mm. .303 British - 11.5mm. I have a good selection of prospective valve caps.

Step 3: Tools and materials.

Picture of Tools and materials.
Basic stuff found around the workshop, except maybe the pipe cutter. This one was only a few bucks at the hardware store.

Step 4: Mark and cut the shell.

Picture of Mark and cut the shell.
I measured up the shell by sizing it up to the valve cap I wanted to use. The area around the base (strangely known as the head) is quite thick as you will see if you look inside the shell after cutting it open. You need to allow for this when measuring up to cut so that the valve cap will sit flush inside when inserted.

Step 5: Prepare the shell.

Picture of Prepare the shell.
The shell needs to be deburred so the valve cap fits properly, and cleaned so the glue will stick to it. Flat file on the end, (hand 2nd cut I think). Small round file inside (poke it around inside the flash hole while you are at it). Then clean inside with scotchbrite and metho to remove burnt stuff. Don't scrub the outside or you will scratch it. Polish it up when it is finished if you think it is required. Ready for gluing.

Step 6: Test fit.

Picture of Test fit.
I drilled a hole through the end of the valve cap by twisting the cap back and forth on a 3mm drill bit held between my fingers. No power tools required. This along with the flash hole will provide a good "key" when filled with glue. Then I test fitted the cap without gluing yet, and removed it again by screwing it onto a tyre valve and pulling.
eblake11 months ago
Is this right 531
I bet 591
sk241 year ago
shoboli2 years ago
iceng3 years ago
Cool stem covers, I particularly enjoyed your novel way of cutting the casing
with a pipe cutter. I would have used a hacksaw and spent hours leveling
and smoothing the the edge.

BTW me guess is 439 casings.

I got that value by counting what was visible in your clear picture
( all your pics are clear and in great focus ) and multiplying by 5.
That is four sides and a center less one that you cut and used.

caarntedd (author)  iceng3 years ago
The winner! I thought there would be more guesses after 200+ views, but I think nobody is really interested, or could be bothered to read the whole I'ble.

BTW, I said guess, not measure,calculate or estimate! :D

Anyway, the total at the time was 421. You are very close regardless of the lack of response. Congratulations and thank you for showing an interest in my stuff.

There can be a lot of negative reaction to anything involving firearms, so I hope that is not the reason for the lack of response. I was just trying to reuse/recycle something that I had lying around.
what is a patch??
caarntedd (author)  munaib rumjaun3 years ago
It's a small icon that gets added to your profile. Members receive them for certain achievments or milestones reached. Pro members are also allocated some patches that they can give to other members as a reward or gift. The member that gives the patch can choose one from the instructables patch library or make their own patch to give away. Click on a few user's profiles and see the patches that they have received. (I only have one so far.)