Materials and Specifications

Why I Make Authentic Cartridges

If I am going to produce something based on a period of history I believe is important, I am going to strive to make this product as much like the originals as possible. I am not an expert on anything, but I research and have spent hours sourcing materials to make products that are faithful reproductions of originals. There is also the idea of trying to help the people of today represent the soldiers of the past as accurately as possible. Whether you are involved in reenactments where there is no public around at all or at events where the public is there and you are able to discuss your knowledge with them, authenticity and quality matter. Most of us have seen poorly made cartridges taken out of well made and authentic cartridge boxes and powder loaded in a quality reproduction rifle-musket. The whole impression matters.

Materials I Use to Make Authentic Reproductions

The cartridges I make are based on the specifications outlined in the manuals and directives issued by the United States Ordnance Department as well as the original cartridges in my collection using period correct materials or materials that closely resemble those used during the war. To be sure, there was other important ammunition produced during the war, yet I have focused my attention on making reproduction ammunition for the .58 rifle-musket based on Small Arms of 1856, the changes introduced at the St. Louis Arsenal, and the Ordnance Manual of 1861.

Paper for Cartridges: The ordnance manual specified the use of what was called “common paper” to make cartridges. This was a “rag” paper usually made from linen. Rag paper is an acid free paper which is not prone to a great deal of fading over time. This paper used in original cartridges varied in color from an off white to a light tan. What this means is that the color of original cartridges that still exist today are close to their original color. Most linen paper today that I have looked at might be close to the right color but differs in thickness to originals. Using a paper micrometer, I have sourced paper that closely matches the paper used on the original cartridges I have in my collection in terms of color, texture, and thickness.

Paper for Williams Patent Bullet Cartridges: The right paper to make Williams Patent Bullet Cartridges is difficult to find today. In fact, I have not been able to find any paper I have been happy with. The paper made today that I have looked at does not match the color, texture, or thickness of originals. After looking at length to find paper that I could use that looked like the paper used in originals with no luck, I was led to dye the paper myself. I use an Indigo blue dye which produces a paper that is a similar color to the original I own. Each batch of paper can vary slightly in color and shows the mottling found with originals.

Thread for Cartridges: The ordnance manual specifies thread to be “of unbleached flax, two strand” (11).  I have a source where I buy unbleached two strand flax thread that looks the same as original cartridge thread in terms of size, color, and construction.

Paper for Cartridge Bundles: For cartridge bundle wrappers, I have sourced a slightly thicker paper than I use for cartridges. This paper is similar in color and using a paper micrometer measures closely to the original bundle wrapper in my collection.

Cartridge Bundle Stamps: The recommendation from the Ordnance Board in 1856 was to have cartridge bundles printed with the following information: weapon, caliber, powder charge, type of bullet, production location, and the year of production. The earliest stamp was printed in 1858 at the Allegheny Arsenal.  The Ordnance Manual of 1861 makes no mention of labels, simply stating that “the wrappers are of different color to distinguish the cartridges for the different arms” (12).  It appears that only the St. Louis Arsenal used this stamp throughout most of the war while others used the stamp for a period of time. Most of the arsenals bundled their cartridges in plain paper wrappers similar in color to the cartridges. The stamps I use are based on original stamps. I have a stamp for the St. Louis Arsenal for the years 1861, 1862, 1863, and 1864. I also have an Allegheny Arsenal 1861 Stamp.

Cartridge Bundle Twine: I use .03 hemp twine to bundle cartridges as specified in the Ordnance Manual.

Specifications for the Cartridges Made by the Columbia River Arsenal

1.  .58 cartridges based on the Small Arms Specifications. The inner powder case is made by hand instead of being punched by a machine but will create a similar product. Cartridge bundle wrappers have the stamp of the Allegheny Arsenal which produced 3,827,000 cartridges in 1861 (13).  A great deal of the ammunition used early in the war was fabricated using this process. This is for an early war impression.

2.  .58 cartridges based on the St. Louis Method Specifications. Cartridge bundle wrappers are stamped illustrating the year of production, 1861, 1862, 1863, or 1864. For impression dates in 1862, you can include Williams Patent Bullet Cartridges wrapped in blue paper or not. For impression dates 1863 and 1864, each bundle includes three Williams Patent Bullet Cartridges wrapped in blue paper. Cartridges with an arsenal date of 1864 should be charged with 65 grains of powder (In April of 1864, Chief of Ordnance George Ramsay issued the directive that rounds would be charged with 65 rather than 60 grains of powder). These cartridges were issued from 1861 through the end of the war. These cartridges would have been primarily used by troops serving in the Western Theater. However, this is not to say that Western Theater troops did not get ammunition from arsenals in the east or that any ammunition from St. Louis was not sent east. The St. Louis Method Cartridges were also produced by other arsenals including Kennebec and Allegheny, so such cartridges would have been issued to troops in the east although it is difficult to say to what degree.

3.  .58 cartridges based on the Ordnance Manual of 1861 Specifications. Cartridge bundle wrappers are plain with no arsenal stamp. For impression dates in 1862, you can include Williams Patent Bullet Cartridges wrapped in blue paper or not. For impression dates 1863 and 1864, each bundle includes three Williams Patent Bullet Cartridges wrapped in blue paper. Cartridges with an arsenal date of 1864 should be charged with 65 grains of powder (In April of 1864, Chief of Ordnance George Ramsay issued the directive that rounds would be charged with 65 rather than 60 grains of powder). These cartridges were the predominant cartridge beginning in 1862 through the end of the war in the Eastern Theater with millions being sent west as well. After January of 1862, the decision was made at the Watervliet Arsenal, with other arsenals to follow, to produce cartridges using the .574 ball. These cartridges would be appropriate to use with Enfield Rifle-Muskets.