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Rocket Ball

The Rocket Ball is a pioneering form of self-contained ammunition invented in 1848 by American mechanic Walter Hunt, featuring a hollow-based lead bullet filled with black powder and sealed with a thin metal cap containing a small ignition hole, which eliminated the need for separate paper cartridges in early repeating firearms.^[1] This innovative design, patented under U.S. Patent No. 5,701 on August 10, 1848,^[2] was initially developed for use in the Jennings rifle, a lever-action repeating firearm produced by the Robbins & Lawrence Arms Company, marking one of the earliest attempts at caseless or integrated ammunition in firearms history.^[1]^[3] Rocket Balls were produced in two primary calibers: .31 (Cartridge No. 1) and .41 (Cartridge No. 2), with the latter containing approximately 6.5 grains of black powder behind a 100-grain projectile, achieving muzzle velocities around 260 feet per second, though the ammunition's low power and tendency for residue buildup limited its practical effectiveness.^[4] Manufactured by firms like Crittenden & Tibbals, these cartridges were sold in tins of 200 rounds for about $10 to $12 per thousand, and they powered the Volcanic Repeating Arms Company's pistols and rifles from the early 1850s until the company's insolvency in 1857.^[4] Despite its shortcomings, such as insufficient velocity for reliable stopping power and the design's obsolescence by the mid-1850s, the Rocket Ball played a crucial role in the evolution of repeating firearms, influencing key figures like Horace Smith, Daniel B. Wesson, and Oliver F. Winchester, whose acquisition of related patents led to the development of the iconic Winchester lever-action rifles.^[1]^[4]

History

Invention

The Rocket Ball was invented by Walter Hunt, an American mechanic and prolific inventor from New York City, best known for patenting the safety pin in 1849. Hunt developed the cartridge during the mid-1840s as part of his efforts to create reliable ammunition for early repeating firearms, addressing the unreliability of paper cartridges and loose powder that required separate loading of propellant and projectile. His experimentation focused on metallic casings to facilitate faster reloading, particularly in lever-action mechanisms, which allowed for more efficient operation in multi-shot weapons. On August 10, 1848, Hunt received U.S. Patent No. 5,701 for his "Improvement in the Construction of a Metallic Cartridge," describing the Rocket Ball as a self-contained, rocket-shaped projectile where the lead bullet integrated the propellant charge within a hollow base. The design drew inspiration from rocket propulsion principles, with the powder-filled cavity in the bullet's rear enabling self-propulsion upon ignition, earning it the name "Rocket Ball." This innovation marked one of the earliest attempts at a fully metallic, caseless cartridge, eliminating the need for external casings or priming. Hunt's Rocket Ball was initially paired with his Volition Repeating Rifle, a lever-action design, and later licensed to Volcanic Repeating Arms, which refined the concept for commercial production.

Early Adoption

The Rocket Ball saw its first commercial production in the Jennings repeating rifle, manufactured by the Robbins & Lawrence Arms Company starting in 1849. This lever-action rifle, based on Hunt's Volition design and improved by Lewis Jennings, was produced in limited quantities, with approximately 5,000 units made before production ceased in 1852 due to mechanical issues and low demand.^[5] The Volcanic Repeating Arms Company, founded in 1855 by Horace Smith and Daniel B. Wesson in New Haven, Connecticut, licensed Walter Hunt's foundational 1848 patent for the Rocket Ball cartridge to develop repeating firearms. The company acquired rights to Hunt's design along with improvements by Lewis Jennings, enabling the production of lever-action weapons that integrated the self-contained ammunition. This licensing marked the transition from experimental invention to commercial manufacturing, with initial efforts focused on adapting the technology for practical use. Production began in early 1856, yielding the first commercial models: lever-action pistols and rifles chambered in .41-caliber Rocket Balls, with some pistols also in .31 caliber. The pistols featured 6- or 8-inch barrels with capacities of 8 to 10 rounds, while rifles offered longer barrels for extended range, all utilizing the innovative but underpowered cartridge. An estimated 1,500 to 3,000 pistols and a small number of rifles were manufactured before the company's dissolution in 1857, reflecting limited output due to nascent manufacturing capabilities.^[5]^[6] Key investors, including shirt manufacturer Oliver Winchester, provided crucial funding—Winchester contributed $2,000—and later acquired the company's assets through the New Haven Arms Company after insolvency. Despite these efforts, early adoption faced significant hurdles, including high production costs from complex machining of brass frames and the Rocket Ball's limited powder capacity, which confined propellant to the bullet's base and resulted in underwhelming ballistic performance of around 56 foot-pounds of muzzle energy. These issues led to sluggish sales and user feedback highlighting insufficient power for hunting or self-defense, constraining broader market acceptance.

Decline

The primary limitation of the Rocket Ball cartridge stemmed from its design, which featured a shallow cavity in the base of the conical lead bullet to hold a small powder charge, typically around 6 to 7 grains of black powder. This restricted the amount of propellant that could be used, resulting in low muzzle velocities of approximately 260 to 500 feet per second and correspondingly low muzzle energy, often around 15 to 56 foot-pounds depending on the caliber and charge. Such performance rendered the cartridge inadequate for practical hunting or military applications, where greater stopping power was required, as the bullet lacked sufficient kinetic energy to reliably incapacitate targets beyond very short distances. The emergence of superior alternatives further hastened the Rocket Ball's obsolescence. In 1857, Smith & Wesson introduced the .22 Short rimfire cartridge, which utilized a copper casing with integrated priming in the rim, providing improved reliability through more consistent ignition and higher power relative to the Rocket Ball's limitations. This innovation addressed key flaws in self-contained ammunition, such as the Rocket Ball's vulnerability to moisture and inconsistent expansion of the bullet base for chamber sealing, making rimfire designs more appealing for repeating firearms. The .22 rimfire's greater velocity and energy, combined with enhanced manufacturing scalability, quickly overshadowed the Rocket Ball in the burgeoning market for portable, repeating handguns and rifles. Compounding these technical shortcomings, the Volcanic Repeating Arms Company, which produced firearms chambered for the Rocket Ball and its variants, faced severe financial difficulties due to poor sales and over-capitalization in manufacturing equipment during its 1855 inception. The company declared bankruptcy in 1857, leading to the sale of its assets to Oliver Winchester and John M. Davies, who reorganized it as the New Haven Arms Company. Production of Rocket Ball ammunition effectively ceased around 1860, with any remaining stockpiles primarily utilized in surplus Volcanic firearms rather than new manufacturing. This corporate failure marked the end of widespread adoption, as the design was briefly evolved into the primed Volcanic cartridge before being supplanted by more effective metallic cartridges.

Design

Components

The Rocket Ball cartridge represents an early innovation in self-contained metallic ammunition, integrating the bullet and propellant into a single unit without a traditional case. Its core structure consists of a solid conical lead bullet, typically in .41 caliber with a diameter of approximately 0.41 inches, featuring a deep hollow cavity in the base to hold the propellant charge.^[7]^[4] This design, patented by Walter Hunt in 1848, allowed for reliable loading in repeating firearms like the Volcanic series.^[2] The hollow base is filled with 6 to 8 grains of black powder, providing the necessary propulsion in a compact, self-contained form that eliminated the need for separate powder measures or paper wrapping.^[7]^[4] The propellant is retained by a thin brass disk or cork cap crimped over the base, which includes a small central hole to permit the ignition flash from the firearm's percussion hammer to reach and ignite the powder without premature exposure.^[7]^[8] Overall, the cartridge measures about 0.70 to 1 inch in length and weighs 100 to 120 grains total, balancing portability with sufficient mass for stability.^[9]^[4] While early prototypes by Hunt exhibited minor caliber adjustments around .54 for rifles, production versions were standardized at .31 and .41 calibers for Volcanic pistols and rifles to optimize performance in lever-action mechanisms.^[4]^[2]

Manufacturing

The Rocket Ball cartridge was produced through a multi-step process that began with forming the lead bullet in specialized molds using pressure techniques, such as simple drop-hammer presses common in 19th-century metalworking, to create an integrated hollow base cavity for the propellant charge.^[2] This casting method allowed for the conical bullet shape with a deep rear cavity running most of its length, typically in calibers like .31 or .41, without requiring separate case components.^[2]^[4] Following casting, the black powder charge—often around 6 grains for .41 caliber variants—was inserted into the base cavity through manual or semi-automated packing, ensuring a dense fill to maximize the limited propellant space within the self-contained design.^[2]^[4] The powder was compressed directly into the bullet's hollow while it remained in or near the mold to maintain structural integrity, a labor-intensive step suited to small-scale operations.^[2] Sealing the cartridge involved applying a thin metal or cork cap over the cavity, often lined with waterproof tissue to prevent leakage, which was then secured via swaging or crimping tools that applied a second pressure to flange the cap firmly onto the bullet's base without relying on adhesives.^[2] This airtight fit was critical for the cartridge's function in early repeating firearms like those from the Volcanic Repeating Arms Company. For priming, Walter Hunt's original 1848 patent specified ignition through a central perforation in the cap, with later variants integrating a percussion primer directly into the seal to improve reliability.^[2]^[7] Production occurred in small-batch facilities, including Walter Hunt's operations in New York and the Volcanic Repeating Arms factory in New Haven, Connecticut, with estimates of several thousand cartridges manufactured annually at peak in the mid-1850s to supply the limited output of associated firearms.^[10]^[4] These tins of 200 rounds were priced at $10–$12 per thousand, reflecting the artisanal scale.^[4] Quality control challenges arose from the manual powder packing, which could result in inconsistent charges leading to misfires, a common issue partially mitigated by refinements in Hunt's priming designs but never fully resolved in the era's technology.^[11]^[2]

Operation

Loading and Firing

The Rocket Ball cartridge, as utilized in Volcanic lever-action firearms, is loaded via a tubular magazine located beneath the barrel, typically accommodating 6 to 8 rounds depending on the model and caliber, such as the .41-caliber variants. Cartridges are inserted into the open end of the magazine tube, often through a loading gate for pistols or directly for rifles, and are advanced by a spring-loaded follower that provides consistent pressure to feed them forward. To chamber a round, the operator lowers the finger lever—which forms part of the trigger guard—causing the breechblock to retract, cock the hammer, and elevate a carrier block that transfers the forwardmost cartridge from the magazine into alignment with the chamber; closing the lever then pushes the cartridge fully into the chamber, sealing it for firing.^[12] Ignition occurs when the hammer, released by pulling the trigger, falls and strikes the integrated primer embedded in the thin brass disk sealing the base of the Rocket Ball cartridge. This primer detonates upon impact, generating a flash that ignites the black powder charge packed directly within the hollow base of the conical lead bullet, without requiring an external percussion cap as in earlier designs. The design ensures the primer is positioned against a fixed anvil or the rear of the chamber, directing the flame efficiently into the powder cavity.^[4] Upon ignition, the expanding gases from the burning powder propel the bullet forward through the barrel, with the hollow base of the bullet expanding slightly due to the internal pressure to engage the rifling for stabilization; the brass base disk typically remains intact or fragments minimally, staying behind in the chamber rather than being expelled like a traditional case. This caseless nature simplifies the mechanism but limits powder capacity to small charges, around 6 to 8 grains, which contributes to the cartridge's modest performance. The spent base remnant is then managed during the cycling process.^[2] To cycle the action for repeat fire, the operator lowers the finger lever again after each shot, which retracts the breechblock to push the spent brass disk forward out of the chamber—often into the barrel where it may be dislodged by the incoming round or manually cleared—and simultaneously advances the carrier to chamber the next cartridge from the magazine, mimicking semi-automatic operation through manual lever manipulation. This process enables rapid follow-up shots, with the tubular magazine's spring assist ensuring reliable feeding under gravity and tension. The design lacks inherent safety features such as a half-cock notch or firing pin block, relying instead on the lever's position to prevent accidental discharge and the firearm's overall construction to mitigate risks like chain-firing from powder residue buildup.^[12]^[13]

Performance

The Rocket Ball cartridge, utilized in early repeating firearms such as the Volcanic pistols and rifles, achieved muzzle velocities of approximately 260 to 500 feet per second, depending on the caliber and barrel length.^[4]^[14] For instance, the .41-caliber variant propelled a 100-grain projectile at around 260 feet per second from short-barreled pistols, while longer 10-inch barrels could approach 400-500 feet per second in rifle configurations.^[4] This modest velocity resulted in muzzle energies of about 56 foot-pounds (76 joules), computed using the kinetic energy formula \frac{1}{2} m v^2 with a bullet mass of approximately 65 grains for the .31-caliber round.^[6]^[15] Due to its low velocity, the Rocket Ball exhibited pronounced bullet drop beyond 50 yards, rendering it suitable primarily for close-range self-defense rather than extended engagements or hunting larger game.^[6] The effective range was limited to 25-50 yards for small game, as the cartridge's underpowered performance failed to maintain sufficient trajectory stability or terminal ballistics at greater distances.^[15] In practical terms, this confined its utility to short-barreled lever-action designs, where accuracy diminished rapidly outside point-blank scenarios. Reliability issues plagued the Rocket Ball, including frequent misfires and hangfires attributed to powder settling within the hollow bullet cavity, which could delay or prevent ignition.^[6] Users often encountered gas leakage around the chamber and occasional simultaneous discharge of multiple rounds, necessitating manual extraction with a cleaning rod.^[15] Compared to contemporary percussion cap ammunition, which delivered 200-300 foot-pounds of muzzle energy, the Rocket Ball was markedly inferior in power but represented an innovative step in self-contained cartridge design.^[6]^[15]

Significance

Innovations Introduced

The Rocket Ball, patented by Walter Hunt in 1848, represented one of the first practical self-contained caseless cartridges in American firearms design by integrating the bullet and propellant powder into a single lead unit. This innovation eliminated the need for separate components, such as the powder and projectile handled individually in earlier systems, allowing for simpler loading and greater reliability in breech-loading firearms.^[2]^[16] A key advancement was its compatibility with repeating arms, as the robust, unitary design facilitated magazine-fed systems without the fragility of prior ammunition types. The cartridge's solid construction enabled smooth feeding in lever-action mechanisms, serving as a direct precursor to modern semi-automatic and repeating rifles by demonstrating the viability of self-contained rounds in multi-shot platforms. The Volcanic Repeating Arms Company implemented this in their lever-action pistols and rifles during the 1850s.^[4]^[17] The base-ignition concept featured a central perforation in the thin metal base cap, allowing flame from an external percussion cap to ignite the internal powder charge, representing a step toward integrated ignition systems without fully eliminating external primers. This approach influenced the development of later cartridges with embedded priming, such as the improved Volcanic cartridge and rimfire designs that incorporated priming compound directly in the case rim for self-contained reliability.^[2]^[1] Material efficiency was enhanced through the use of lead for both the projectile and the hollow "casing" that held the powder, creating a monolithic design that was more durable and waterproof than paper cartridges, which were prone to degradation from moisture and handling. This reduced manufacturing complexity and improved field performance by minimizing parts and assembly steps compared to multi-material paper alternatives.^[4]^[17] Hunt's patent (U.S. No. 5,701) exerted significant influence on subsequent firearm innovations, being referenced in numerous 1850s patents for cartridge and repeating arm designs that built upon its integrated principles.^[2]^[18]

Legacy in Firearms

The Rocket Ball ammunition served as the direct predecessor to the improved .41 Volcanic cartridge, introduced around 1855 by the Volcanic Repeating Arms Company, which incorporated an internal priming disk at the base to enhance ignition reliability over the original design while remaining caseless.^[7] This evolution marked a key step toward self-contained metallic cartridges, transitioning from the limitations of percussion systems.^[5] The assets of the Volcanic Repeating Arms Company, including patents and designs derived from the Rocket Ball system, were acquired by Oliver Winchester in 1857, forming the New Haven Arms Company under Benjamin Tyler Henry.^[19] This acquisition directly influenced the development of the Winchester Model 1866 lever-action rifle, which adopted an improved toggle-link mechanism and rimfire cartridges, standardizing metallic ammunition in repeating firearms and paving the way for the iconic Winchester lever-action lineage.^[5] Surviving Rocket Ball-era firearms, such as Jennings repeating rifles, are highly prized by collectors due to their scarcity and historical significance, with auction values typically ranging from $3,000 to over $10,000 based on condition, engraving, and provenance.^[20] ^[21] Modern replicas of descendant lever-action designs, produced by manufacturers like Uberti, enable historical shooting enthusiasts to experience the mechanics of early repeating arms using contemporary metallic cartridges.^[22] Rocket Ball firearms and ammunition are prominently featured in collections at institutions like the Cody Firearms Museum at the Buffalo Bill Center of the West, where examples illustrate early repeating mechanisms.^[23] Scholarly analyses recognize the Rocket Ball as a critical bridge between percussion cap ignition and fully integrated cartridge systems, facilitating the shift to reliable, self-contained ammunition in the mid-19th century.^[1] The integrated propellant-bullet concept of the Rocket Ball has echoed in modern caseless ammunition developments, such as those explored by military programs for lightweight, reduced-weight firearms that eliminate traditional brass cases to improve portability and logistics.^[24]

References

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Early Caseless Ammo: The Rocket Ball - The Truth About Guns
Mar 30, 2017 · Patented in 1848, Hunt's Rocket Ball design sought to eliminate the need for traditional paper cartridges, which were state-of-the-art for more ...
[2]
RARE .54 CALIBER HUNT & JENNINGS “ROCKET BALL”
The "Rocket Ball" is a self-propelled, self-contained .54 caliber round with a lead bullet, powder, and cork base, designed for Jennings rifles, patented by ...
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Original Volcanic “Rocket Ball” Cartridges - Forgotten Weapons
Aug 24, 2020 · There were two calibers made; the .31 (Cartridge No.1) and the .41 (Cartridge No.2). Both were sold in tin boxes of 200 rounds, originally costing $10/thousand.
[4]
Walter Hunt - Lemelson-MIT
He patented the safety pin on April 10, 1849 (U.S. Patent No. 6,281), and he willingly sold rights to it for just $400. Sales of the invention would later earn ...
[5]
Rocket Balls and the Volition Repeating Rifle
Apr 25, 2015 · In 1848, a gentleman named Walter Hunt from New York, invented a new type of metallic cartridge that he called the Rocket Ball. A copy of ...
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US5701A - Walter hunt - Google Patents
A new and useful Improvement in the Construction of a Metallic Cartridge, made entire with the ball,1'or fire-arms, which I term a rocket-ball.
[7]
First Lever Action Rifle Moments Include Henry, Winchester, Marlin
Aug 17, 2023 · Walter Hunt developed a metallic cartridge called the Rocket Ball with its powder and bullet contained in a single package. He just needed to ...
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Volcanic Repeating Arms - Wikipedia
Wesson to develop Walter Hunt's Rocket Ball ammunition and lever action mechanism. Volcanic made an improved version of the Rocket Ball ammunition, and a ...
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[PDF] Volcanic and Henry firearms - American Society of Arms Collectors
The new company was valued at 450,000.00 dollars and the first firearm to be produced was announced in 1886 and this was called the model 1866 which was the ...
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Based on Walter Hunt's Rocket Ball cartridge patent (#5701, August 10, 1848) ... Volcanic Repeating Arms Company nearly went under in early 1857.Missing: licensing | Show results with:licensing
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Levergun Leverage - GUNS Magazine
In 1855, partners Smith & Wesson, Horace and Daniel, formed the Volcanic Repeating Arms Company to improve upon the Rocket Ball lever action design of one
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Volcanic Rifles & Pistols - Winchester Collector
The Volcanic Repeating Arms Company began producing rifles and pistols in early 1856. These weapons used the “Rocket-ball” cartridge.Missing: numbers | Show results with:numbers
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A Look Back (And Forward) At The 1873 Winchester
Oct 1, 2013 · Rocket Ball ammunition held the powder charge within the hollow base of the bullet, and like all forms of so-called “caseless” ammo it has never ...
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Rimfire vs Centerfire Arms Race - Rock Island Auction
In 1857, Daniel B. Wesson's .22 Short rimfire round set off an arms race in self-contained cartridge development that continues today.
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Smith & Wesson acquired Lewis Jennings' improved version of inventor Walter Hunt's 1848 “Volition Repeating Rifle” and its caseless “Rocket Ball” ammunition, ...
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Jun 30, 2016 · Oliver Winchester was left owning the control of the fledgling Volcanic Arms Co. for which he was a majority shareholder and corporate vice ...
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VOLCANIC SELF-CONTAINED AMMUNITION - Collectors Firearms
Jun 12, 2025 · ... Walter Hunt's Rocket Ball, a loaded bullet, U.S. Patent No. 5,701, issued on August 10, 1848. The tale winds its way through the largely ...
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Federal .41 Caliber Self-Contained Volcanic Revolver Bullet
... diameter, .70-inch length, 113 grains weight ... 41 Caliber Self-Contained Volcanic Revolver Bullet ... 436-inch diameter, .70-inch length, 113 grains ...
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Manufacturing Cartridges in the 19th Century - Part III
Apr 5, 2015 · While we have studied cast lead bullets in the past, by the 19th century, the casting method was considered too slow for mass production.
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Dec 25, 2022 · In 1856, Oliver F. Winchester established a small factory in New Haven to manufacture Volcanic-pattern pistols and rifles. This firm, operating ...
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Apr 28, 2015 · Even though the Walter Hunt patent claimed that that the rocket ball was self cleaning (as noted in our last post), it didn't work nearly as ...Missing: licensing | Show results with:licensing
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May 5, 2014 · The Volcanic Arms Company went bankrupt in 1857, and was bought up by Winchester. Winchester would continue to produce Volcanic pistols for ...Missing: competition | Show results with:competition
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Race for the Fastest Bullet | Rock Island Auction
Sep 23, 2024 · "The cartridge, ball, caliber .30, Model of 1906" could achieve a muzzle velocity of 2,700 fps, a nearly 400 fps advantage over its .30-03 ...
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Chapter 1: The Henry is Born. The Volcanic Repeating Arms Company began producing rifles and pistols in early 1856. These weapons used the "Rocket-ball ...
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Cartridge Advancements - Carbine
The American role in metallic cartridges began with Walter Hunt, the inventor of the safety pin and fountain pen, who patented his "rocket ball.
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May 20, 2016 · When the firing pin of the revolver's hammer struck the rim of the cartridge, the priming ignited the powder, firing the bullet, leaving the ...
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https://www.michellawyers.com/wp-content/uploads/2018/03/2018-03-05-Exh-27-30-to-Dec-of-AMB-ISO-Plaintiffs-MSJ.pdf
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In 1855, Winchester became a stockholder and director of the Volcanic Repeating Arms Company, a firearms manufacturing firm that brought together the talents ...
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Sep 9, 2017 · Estimated Price$7,500 - $11,000. Log In to use Wishlists Log In ... Rocket Ball" cartridge. They were manufactured by Robbins & Lawrence ...Missing: value | Show results with:value
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(A) RARE SMITH-JENNINGS REPEATING RIFLE. - Morphy Auctions
Bidding. Current Bidding. Minimum Bid: $2,500.00. Final prices include buyers premium: $3,300.00. Estimate: $5,000 - $7,000. Number Bids: 3. Auction closed on ...
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1860 Henry Rifle | Uberti USA Replica Rifles and Revolvers
The Uberti 1860 Henry is an absolute favorite in N-SSA target shooting competitions, thanks to its historic looks, fast handling and great accuracy.Missing: Volcanic | Show results with:Volcanic
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[PDF] VOLITIONAL RIFLES, THE ORIGINS OF THE WINCHESTER LEVER ...
Mar 26, 2024 · Rocket balls were still separately primed, and the Hunt rifle has a ... Walter Hunt, Combined Piston Breech and Firing Cock Repeating Gun, U.S. ...<|control11|><|separator|>
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Jul 5, 2013 · From the Volcanic rocket ball of the 1850s to the Gyrojet of the 1960 ... Historical Firearms (Tumblr) · Joel's Gulch · View From the Porch ...