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All other methods I've found online suggest using a candle or lighter to heat up the brass, which will partially melt the plastic. However, common sense says that leftover gun powder (which is highly flammable) that may be left over in an expired shell probably shouldn't be exposed to an open flame, unless you really desire to be blown to pieces. I personally don't, so I've devised a way that makes it somewhat safer. I don't take any responsibility if you're a dumba$$, though.

Materials:
Spent shotgun shells
Iron
Vice grip
Rag/scrap fabric
Knitting needle/chopstick or similar tool
2 sets of pliers

Step 1: Remove the Primer

Using a shotgun shell reloader, a hammer and nail, or any other method you choose, remove the shotgun primer.

Step 2: Clean the Shells

Take a piece of scrap fabric or a rag. Carefully wipe down the outside of each shell and then wrap the rag around something like a chopstick or knitting needle or similar tool to really clean inside the shell. Be careful to clean out any remaining gun powder that may still be in there.

Step 3: Wash Your Hands

Get any gun powder off your hands, clothes, and work area.

Step 4: Set Up Your Iron

Set up your iron in some way that will securely hold it with the flat side up--I used a vice grip. Put your iron on a medium high/high setting.

Step 5: Start Melting the Shotgun Shells

Put your clean shotgun shells on the iron (brass side down). You can start by doing one or two at a time, then work up to doing as many as will fit on the iron. The length of time you leave it on the iron depends on several factors:
--The age of your iron
--The brand/gauge of shells
--What material the wad is made out of (plastic ones melt easier than ones that have felt and cork)

I have an old iron, I used a lot of Winchester 12g shells that all had plastic wads, and I filled up my iron and left them on there for about 2 minutes.

Be smart--don't walk away and forget what you're doing and be careful when kids and pets are around

Step 6: Remove the Brass

Take a shell off the iron and, using one of the pliers, grab it a little bit above the brass. Take the other set of pliers and grab it right on the brass. Twist in opposite directions a few times and it should pop right off. If it's not turning, put it back on the iron for a few more seconds. The brass is now separated from the plastic.
What would you use the brass for? Do you do this to take in the brass for recycling?
If any of you have the metal discoloration from heating them, I had some. Just use some metal polish and it will polish up better than it was. A bottle is only 2-3.00 and will do many shells. Use paper towels or an old rag.
I did this after reading your Instructable! Got to say that this is the best way to remove the plastic from the metal!!!! I have tried several other ways, a propane torch, boiling 20 at a time, just to name a few. None were as fast or easy as your way. I didn't wipe the shells down or anything and had no problems. I had 200 hundred to remove for leather projects for me and woodworking for my son. Started out doing 5 at a time but in no time I was doing 25 at a time, just needed to regulate the iron temperature with my timing. Thanks for a Hot idea. lol
Did this years ago with a pan on the stove. My only mistake was assuming it was brass, turns out it was coated steel.
There won't be any danger from unspent powder blowing you to bits, powder may smoke and stink up your house, please do this outside or in a well ventilated area! Good Instructable.
<p>Very nice!</p>

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