How to make percussion caps without a die II

[DragoonRick]

The next step is to smooth the. bevel and cut the star shape .  I also filed v groves down the hole.  These star cuts and v cuts allow the cup to form smooth folds.  With out them the disk form into off sided useless shapes.

[DragoonRick]

More photos. I made a mistake of drilling the hole out to 1/4 inch. Is to large a diameter for the caps. But it demonstrates the method.

[ShotgunDave]

Nice work Rick.

[DragoonRick]

Photo of forming board being used

[DragoonRick]

Charging with paper roll caps.  The star punch workers very well because the star points grip the percussion cup. They fire reliably. I have not tested them at the range.  The 1/4 inch hole ic to wide for paper caps. The 3/16 in. Hole works best with paper caps. The 1/4 inch wide cap fits loose.  I will try 7/16 hole punch for paper caps.

[ShotgunDave]

So you press the cap in? That's a good idea. I didn't think of that.

[DragoonRick]

The whole process is simple and cheap. When I push the copper or aluminum disc down the hole I use a tapered wooden dowel of proper size to set the paper caps in the bottom of the. Cup.  Then push it out the bottom of the board.

[DragoonRick]

I’m posting this to demonstrate cap making as I decided I needed a few more.  I punched out enough for 70 caps from copper foil.  You can see a few completed caps made with older red ring caps. Those never seem to fail if made properly. I have on cap making hole that doesn’t have the star or v cuts in the hole.  The result is a copper disk jammed through. There are a few completed cap.

[DragoonRick]

Here are a few I assembled in about 10 minutes not including the time of punching out the disc. Another 5 minutes. 21 completed caps.

[Zulch]

That’s pretty ol cool there Rick! Great pictures too. Thanks man. Tim

[DragoonRick]

I’m really grateful for all of you who have read this thread.  And also for the forum managers who have supported this research and effort.
It isn’t “the end”
Rick

[Captainkirk]

Please carry on! Following with much interest!

[ShotgunDave]

We're very grateful as well! This is much needed information. Thanks for taking to time to help us.

[Zulch]

Rick, your extensive efforts and attention to detail are not in vain. You are giving a lot of your time on this thread and it’s most appreciated my friend😊👍 your storytelling explanation and pictures are very easy to follow. Thanks again , Tim

[DragoonRick]

FYI! 
I saw for myself that Tractor Supply is stocking German made paper roll caps.
On this mornings listing Midway USA has no percussion caps in stock.

   My next series of notes will be a can of caps charged with paper roll caps. I haven't made more than a few of those. I’d like to see how they function.