Once upon a time you could buy "range/practice" ammo that was totally coated in nylon jacket/shell to provent lead exposure on indoor ranges - it was redesigned for use in slow moving 38's and sold as "Cheif's Special" ammo by S&W then the process was bought by Federal who got bought out by Blount (which owns CCI, Speer, RCBS etc). My thought is to have a nice 180 or heavier soft lead bullet designed for the 300 whisper coated in Nylon to save on cost that will expand at subsonic velocities and not cause any problem with suppressors - here's a quote from the internet about how it was applied.
Quote:
"Disclosed is a lead bullet having a coating comprised of a thermoplastic composition of molybdenum disulfide and Nylon 11. Nylon 11 per se and other coatings are also disclosed. The coating minimizes or prevents deposition of lead along the barrel and other mechanisms of a firearm. To apply the coating, the bullet is initially degreased and heated to clean its surfaces. A phosphate coating is applied and the bullet is heated to a temperature of at least 425° F. The heated bullet is then disposed in blended molybdenum disulfide and Nylon 11 powder, Nylon 11 per se, or other coating materials to obtain a coating thickness within a range of 1-12 mils. The coated bullet is subsequently heated to at least 367° F. to fuse and to densify the coating on the bullet. "
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You could use a cast bullet in the process and then use a nylon or other coating (epoxy paint maybe?) - would anyone be interesting in discussing with me, either on the board or off line?