Guys

Thank you so much for the fast and informative responses, with regards to the set up - here is what I have:

Lee bottom pour melting pot
I have tried several alloy temps between 700 - 900 degrees
I put some powdered flux in the mix but will now need to pay closer attention to the amount
I coated the mold with a spray can "Mold Release" before using it and actually before each time that I attempted to use since
I do have a hot plate that I heat the mold up with before and during the casting session

It appears like I just need to tweek something to get it right - with regards to the output I actually have had success with the larger size split shot but not the smallest one - the only one I am really intrested in. I do have some tin but have not used it yet as I am unsure on the percentage to lead to use??

I will attempt again today and take some picture along the way to show my results to provide a better base for further suggestions.

Thanks again for all the advise.

Tom D