Well, it's been almost two years since I first started this post about working down lead into a useable, shootable alloy. Some things I have done/learned...
I bought some Linotype lead to mix with my wheel weight/scrap lead to make harder bullets. For .30 caliber rifle projectiles, I put a small amount of linotype into my Lee pot, maybe 10%, then lube and install a gas check with a Lyman sizer. This alloys me to shoot .30 caliber bullets at 2000 FPS, and get accuracy of 1.5" at 100 yards with a CZ 527 carbine in 7.62 X 39 caliber.
I worked down all of that scrap lead (lead pipes, flashing) by melting it in a cast iron skillet on a Coleman stove. Took two days and a gallon of Coleman fuel. All done outdoors of course to alleviate lead vapors.
The scuba diving weights and 30 pound pie shaped ingots I cut up with a chop saw (Miter Box Saw), ruining the blade in the process. A replacement blade was only $8.00, so it was worth it, it would have taken forever to melt down those larger ingots in a skillet.
When I got done, I had three five gallon buckets full of lead ingots, ready to be made into bullets. Should be a lifetimes supply, as I have bean shooting my practice rounds into a bullet trap, a box full of old books that stop any .357, .44 Magnum and 9MM cast lead bullet. When the trap gets full, packed full of projectiles, I disassemble it and recover the lead, making new projectiles. the last time I disassembled my bullet trap I got enough lead to make 750 124 grain 9MM bullets...
My best results have been the 7.62 X 39 bullets, some 240 grain .44 Magnum bullets that will shoot one ragged hole at 50 yards from a Rossi Model 92 carbine, and 9MM bullets shot through a Glock 17 with a Lone Wolf barrel. Also, 180 grain 8 MM Mauser bullets, hard lead alloy with a gas check, loaded to 1800 FPS and shot through a Yugoslavian Mauser, very accurate and quiet...
Bullet casting is fun, I have learned a lot about it in the last few years, and I'll continue to search for that perfect bullet and rifle combination.