The problem with making powder is; It is a dangerous hobby. We had a plant called Badger Ordinance which was made explosives and powder for the second world war, and they were always having things blow up. Even under strict conditions, accidents can happen. Consistancy is hard to achieve with primitive equipment. Your homeowners insurance might have something to say about the idea.I would guess with the new Federal Restrictions out there, Tobacco, Alcohol and Firearms might pay you a visit. Also if you want cheap powder and want to be primitive, get some Goex. Goex has been in business for ever. You'd technically be shooting the same stuff today that they were shooting many many years ago. If you purchase the powder in bulk, you can get it for as little as $11.00 - $13.00 a pound.

Another source for cheap powder is wait for a Wal Mart (if they still carry the stuff) to have their annual sale. I used to pick up Pyrodex and Triple Se7en real cheap compared to normal prices.

As for casting roundball.. that is a great hobby. Get a LEE mold. They do not break the bank and cast a very good roundball. I have been casting my own for many years.