A question on card wads.

[Meaty]

I have fairly recently started reloading for my Martini Henry Mk IV B and brought a 12mm diameter card wad punch (the cast iron type that you whack with a mallet) to make the over-powder wads with. My case inside neck diameter is 11.91mm / 0.469", or there about's, so thought the 12mm wad punch would be the one to go for. What I wasnt expecting was the punch to be 1/2" diameter and the wads to be a right pain in the derrière to get started and seated properly. The manufacturer then stated that the 12mm and 1/2" punches are the same and doing a quick web search this same scenario is repeated with other makers.
I made up a 10mm stainless rod with a 2mm chamfer one the end and now press the card wads into a 1/4" piece of silicone sheet and they turn out looking a bit like a cup cake case with a nice uniform crinkled edge that gives and moves to whatever variance I get with the case neck. They grip nicely as well. Can anyone see anything wrong with doing this?
Just as a footnote, the last batch of ammunition I made up with these wads seemed much more accurate than my previous efforts but it could have been down to a number of other things as well.

[dromia]

So long as it is a consistently crinkled circumference then it should be fine.

A fired 45 calibre case, say 45-70 can make a good cutter, sharpen the outside of the case with a deburring tool, drill out the primer pocket to allow a dowel or rod to be inserted to push out the cut wads and use a soft faced hammer to tap the case with, I like the Thorex line from Sheffield, and away you go.

[Meaty]

Thanks Adam,
I was going to turn a wad cutter and get it case hardened at work but time (or the lack off) got the better of me and I brought one instead-looks like I will be making one after-all emrolleyes

[dromia]

A 45 case does work well and is nice and low tech for unskilled, hamfisted people like me.

[Meaty]

I shall have a rummage around when I am next at the range.

[dromia]

Pm me your address and I'll put some retired 45-70s in the post to you.

[Meaty]

That's most kind of you-thanks.