Starting my first horn

[PetahW]

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There's no flies on you, Kevin - so far, so good.   

For the plug, I trace the outline of the big end of the horn onto a 3/4" thick piece of wood and cut out the shape with a saber saw, just inside the tracing (to allow for the horn thickness).

Then I work down the diameter of the plug gradually with a sanding disc, then files, until it slides inside the horn at least 3/8" (+/-) - leaving the rest of the plug proud for the time being.

I epoxy & pin/peg the plug in place, before shaping the proud section with the sanding disc, then files, to a slight dome shape.

I you want a filler hole in the plug, either buy a ready-made brass plug from Track of the Wolf, or drill a hole in the center and ream it out for a tapered peg that had a knob left on the end for the powder horn strap.

A period correct rear strap holder is also easily made by bending a nail into a "U" shape, cutting off the ends evenly, then drilling two small blind holes to accept the "staple", which I also epoxy in place.


   

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[BEAVERMAN]

Hey kevin, how's the horns coming along? inquiring minds want to know!

[KDubs]

 ah gee beav,

 actually I'll be back at it today, had a few delays like putting a 40 sgft new tile countertop , sink/disposal and replacing my water pressure tank.. I've been busy.
 I did pick an inexpensive disc/belt sander. got the base plug in.
 hoping today to get her all finished up and then I'm planning on making (attempting) a flat horn with the other horn I got from you.
 
 Hoping Christmas will be a good one, gave out my wish list for everything and anything Black powder. 
 I'l post up a pic later today when Its done.kevin
 
 

[Bigsmoke]

Kevin,

Tell me about the disc/belt sander.  Where did you get it?  What size sanding belt does it use?

For the sanding disc, I think you will be happy with something anywhere between 60 grit to 90 grit.  For the belt, 60 grit is good to work down the sides of the horn, 220 is a good in between general purpose belt and 400 is fine enough to give you pretty good finish results.  I always give it a light
hand sanding with 400 or 600 grit paper and then finish it off with 0000 steel wool.  CdA Power Tool used to carry a lot of different belts and discs.  Probably still do.
Frankly, I always thought that to be one of the more important pieces of shop equipment one can have.  Good on you, lad.

John (Bigsmoke)

[rollingb]

I bought one of these Performax® 4.3-Amp Corded 4"x36" Belt/Disc Sander  about 20 years ago from Menard's (https://www.menards.com/main/home.html),.... and it's been a good one. 

Just type in "belt sander",.... current price is $110.00 

[BEAVERMAN]

I've been using 3 harbor freight combos for 15 + years and all have served me well, having an inexpensive bench top is fine, they work, don't scrimp on belt and disc quality, and that all depends what your sanding with it, I have one set up vertical with a blackhawk sharpening base and jig  and 360 belt and that sets next to my lathe for a quick tune up on my turning chisels  when needed, another is strictly for wood and horn and the third is for metals just makes life easier when your getting serious about building stuff!

[KDubs]

 Just to get going I picked up a skil 6" disc 4x36 belt sander .
 Really really cheap.   I will eventually get a better one that's not all plastic. 
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Here's the finished horn, for the most part . need some clean up.
 Piece of Oak wine barrel stave for the butt.  Left the horn natural shape rather than round it.
 Black ink band with 4 brass staples.
 Pretty basic but a good learning experience.
 Kevin

[RobD]

Good job, kev!   

[Butler Ford 40]

Looks good!   

[KDubs]

My brother in law shoots a modern inline M/L so I'm going to scrim his last name ( Raia)  on this one and send it to him in an antler mount. try and convert him.
 I ll finish it tomorrow and post a pic before i send it off.
 
 Started a flat horn attempt this morning, went OK , not perfect but again I'm learning.
 tried the hot air gun, I found it too hard to keep 2/3 of the horn hot enough for flattening. It will work great for rounding a horn tho..took forever too, went thru a J Giels, buckcherry and and Alice cooper CD.  rock on!
 
Tomorrow Ill try a hot plate and crisco, in a pan of course. 

kevin

[BEAVERMAN]

My brother in law shoots a modern inline M/L so I'm going to scrim his last name ( Raia)  on this one and send it to him in an antler mount. try and convert him.
 I ll finish it tomorrow and post a pic before i send it off.
 
 Started a flat horn attempt this morning, went OK , not perfect but again I'm learning.
 tried the hot air gun, I found it too hard to keep 2/3 of the horn hot enough for flattening. It will work great for rounding a horn tho..took forever too, went thru a J Giels, buckcherry and and Alice cooper CD.  rock on!
 
Tomorrow Ill try a hot plate and crisco, in a pan of course. 



kevin

Do yourself a big favor and get a candy thermometer and put it in the oil, no hotter than 300 to 315, submerge the horn , when you start seeing a bunch of tiny bubbles coming out of the horn pull it out, you may need to repeat the process a couple times until the horn is pliable, then start to flatten, don't try to flatten it all in 1 squeeze, may take a couple 3 times to get it to where you want it, good luck!

[KDubs]

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Viola!    I think I'm done, not sure. 
 My wife is off thrift store shopping for a fry daddy.
 Just seems the best option.
 Kevin

[ridjrunr]

That looks great! One guy from the Horners guild recomended to use suet right from the local butcher shop, claiming its animal by product and so is horn. Not sure if that hocus pocus or not but I did just that and its been working realy well. I dont know if it was mentioned yet but some oblong forms close to what you want the flat horn to end up as is pretty important imo. It keeps it from colapsing.
Hard to explain, ill try n get picture.
Your scrim is impresive, i tried a black bear one time but the guy said it looked like a hipo so i had to redraw it, luckily i had only penciled it on when i showed him🤓

[Butler Ford 40]

Kevin, if that doesn't make him want to drill a hole on the side of that in-line, I don't know what would!  Well done, my friend!!!

[BEAVERMAN]

  WELL DONE KEVIN!   

even with a fry daddy I still use the candy therm to get the temp correct!