Free Shipping This Month!
Cart 0

Melting Instructions

How to Reuse Ballistic Gelatin


The key to our cost saving synthetic ballistic gelatin is its re-usability.   These processes are called melting and molding.  These two processes are what propel us above everyone else.  Pay close attention to all warning!  It is paramount for your safety to heed these warnings during both the melting and molding process.  We have listed the warning at the top, and again where they apply in the process.


  • After washing the block, all water must be removed; failure to do so will ruin the block during melting.
  • Never heat the gelatin above 2800F.
  • Liquid ballistic gelatin is HOT!
  • Never use wooden molds only use molds that are heat tolerant non-porous.
  • Never place your mold containing molten ballistic gelatin on any combustible surface.
  • Never use plastic utensils or strainers they can melt.

 Tools Needed

  • 1 – Electric cooker
    • For FBI size blocks we suggest Hamilton Beach 32182 18-Quart roaster oven or similar (it need to have a temperature control)
    • For Air Rifle block we suggest Crock-Pot SCR300SS 3-Quart slow cooker or similar
  • 2 – Silicone pot holder gloves
  • 1 – Large metal spoon
  • 1 – metal strainer
  • 1 – thermometer – Suggested Taylor Classic Instant-Read Pocket  
  • 1 – mold – purchase from us

Melting process

  1. Wash the outside of the shot ballistic gelatin with water and mild soap to remove as much debris as you can.
  2. Cut the wound tracks out.
  3. Cut or tear the ballistic gelatin into small pieces ** TIP: uniform sized pieces melt more evenly and faster.
  4. Remove any (gunpowder, bullets, arrowheads, or dirt) that was inside of the ballistic gelatin block. ** TIP: Most people discard the wound track and purchase addition ballistic gelatin by the pound and added it.
  5. Wash the cut pieces with mild soap and water.
  6. Dry the cut ballistic gelatin with a cloth or towel removing all water. ** WARNING: DO NOT MELT A WET BLOCK OF BALLISTIC GELATIN! ** TIP: We suggest letting the ballistic gelatin sit in the sun to dry for several hours.
  7. Place all of the cut pieces of DRY ballistic gel into above listed cooker.
  8. Heat the ballistic gelatin to 2700F. ** WARNING: DO NOT HEAT THE BALLISTIC GELATIN ABOVE 2800F!
  9. Check the ballistics gelatin every 30 minutes with a thermometer.  Cooking time depends on the quantity of ballistic gelatin placed in the cooker.  Generally melting time is between 1 to 4 hours. 
  10. Once the product is completely liquid, the melting process is complete.

Molding Process

  1. Place your mold on a flat stable surface. **WARNING: NEVER PLACE YOUR MOLD ON GLASS, OR ANY COMBUSTIBLE SURFACE!
  2. Place your strainer over the mold. – Only need if you have foreign material in your ballistic gelatin
    1. Slowly pour the ballistic gelatin through the strainer into the mold. ** WARNING: THE BALLISTIC GELATIN IS VERY HOT!  ** TIP: Wearing heat proof gloves is recommended.
  3. During the poring process, air bubbles will form and they must be removed to keep the calibration.
  4. Remove the insert pan from the electric turnkey cooker.
  5. Preheat a turkey roasting oven to 2650F.
  6. Place your mold containing the liquid ballistic gelatin with bubbles into the roasting oven and place the lid over the mold.
  7. Warm the ballistic gelatin, 2 to 4 hours (cooking time will vary depending on the quantity of ballistic gelatin)
  8. Check every 45 minutes to one hour to see if all the bubbles have risen to the top. **TIP: Not all bubble will be gone just majority of them.
  9. When most of bubbles are gone, turn the roasting oven off, and let cool for 12 to 24 hours.
  10. Remove the cooled block from the mold. ** TIP: loosen the ballistic gelatin from all sides before pulling it out.


The glossing step removes all fingerprints or small tears, which occur during removal of the block from the mold.  This step can be entirely skipped if you like.

  1. Place the ballistic gelatin block on a non-combustible surface.
  2. Using a hair drier or heat gun, heat the surface of the block.  It will turn lightly liquid. **WARNING: DO NOT TOUCH THE BALLISTIC GELATIN!
  3. Let cool 5 to 10 minutes.