I was thinking I could have an undersized mold made, maybe 10 thousenths undersized, then jacket the bullet using electroplating. I did this to seals for steam valves in the Navy but I'm not sure if lead can be electroplated or not.

I think it can. I think bullet companies like Ranier and Berry's offer electoplated bullets. Aslo, I think Speers TMJ (total metal jacket) is plated. I'm not sure how you would do it, and it sounds like a lot of work, but there would be the satisfaction of shooting bullets you made.

James

It would be time consuming (as if casting bullets wasn't), and I don't see how it would perform better than a gas checked lead bullet.

I don't think you could get "match grade" bullets this way.

Jimro

Remington for example has done this for years and makes very good quality bullets by this method .A good example is the 80 gr .243 power lok bullet. They run them through forming dies after plating them.The jackets done by this method are very consistant and shoot well.