Cheap horn question

[tmdreb]

I don't mean to insult the expert craftsmen on this board, but I have a question about one of those cheap overseas horns.

I bought one of these things a few years ago, and after seeing what they're supposed to look like on here, I've decided mine is inadequate.

Is there any way I can make a decent looking horn out of what I have already, or is it a lost cause? It started out extremely shiny and black, and I've managed to take some of the shine out with steel wool.

Thanks.

 

[bob1961]

a picture if ya can would be the best help :v ...........bob

 

[soggy]

:hmm: Gotta agree with Bob.........try and post a picture of what you have. Most likly we can offer suggestions that will "fancy 'er up" for ya.
Horn is quite easy to work with, both shaping and colouring.
Soggy

 

[Harddog]

Yeah, post a picture and we can give you all kinds of ideas to spruce it up.

Randy Hedden

 

[tmdreb]

Here are some pics:

Horn
Horn from a different angle

I tried to take some of the sheen off with steel wool. It doesn't appear to have helped much. The backdrop is a jacket I made, as proof that I can perform some work with my hands!

 

[Harddog]

Phil,

The first thing I would do is get rid of the leather thong that is now the powder horn strap. Make a 3/4' wide leather powder horn strap with a brass buckle for adjustment or invest in one of the woven straps.

Secondly I would saw the ******** off and leave only about 1/4' of ******** that I would then file into a domed profile and install a wire staple for strap attachment. After reshaping the ******** I would make sure all the old finish was off the newly shaped ******** and stain the new domed plug a very dark walnut color.

I would preferably like to straighten out the spout hole so that it is in line with and concentric with the outside of the horn instead of at an angle with the horn. I would probably just refile the shape of the throat of the horn to try and get it more in line with the spout plug. I think I would also extend the throat back up the horn about another inch. The spout tip is to big around so file it down and just leave a lip at the very end of the spout or file the spout into an eight sided octagon spout.

I would also get rid of the big round spout plug and replace it with a flat profile spout plug. I would probably just hand whittle on to fit.

I would also file off all the concentric rings on the spout/throat and just leave one ring for attaching the horn strap. The rest of the spout and throat would look good if it was just plain and tapered down from the step down of the body of the horn into the aforementioned lip at the very end of the spout. I would make sure and leave one ring right at the natural balance point of the front of the horn. Hold the horn with two fingers of one hand under the ******** and one finger tip of the other hand under the spout of the horn so that the horn balances and lays the way you want it to lay when worn. Mark where your one fingertip is and leave one ring at or just forward of your mark toward the spout. This determines where you will attach the front part of the strap. The staple in the ******** will be in the middle of the ******** and horizontal to the placement of your two fingers that balance the rear of the horn.

This would make into a nice looking horn.

Randy Hedden

 

[tmdreb]

Thanks!

That really helps a lot. How does one install the wire staple? I completely agree about losing the leather thong. I was thinking about making one of these to attach to the horn.

 

[Harddog]

Thanks!

That really helps a lot. How does one install the wire staple? I completely agree about losing the leather thong. I was thinking about making one of these to attach to the horn.

Just get yourself some stout wire, (a thick wire coathanger will do fine), sharpen both ends of the wire with a file and bend the ends over to form two legs with a span between them according to the size of strap you will use. Mark where the two legs will be on the ******** and drill a couple of holes undersize of the wire legs and just pound the staple into the holes with a mallet.

Randy Hedden

 

[Goldhunter]

To go one further along with Harddog, you can pound the same piece of wire into a square shape, before bending, on a hard surface like your bench vice. This can give it a "forged" look, if you like. Can add some roughness to the overall look, if you like that approach.

 

[tmdreb]

So far, I've got the ******** sawed off, and have started on filing it even and shaping it. Unfortunately, the wood is such that it is cracking around the edges, and some small chunks have either fallen out, or are about to. I suppose this horn will have to have "character" to it.

Are there any recommendations for the finish? All the beautiful reproductions I've seen here, as well as pictures of originals do not have the shiny, polished finish mine has.

 

[Harddog]

Phil,

If the ******** is chipping and you don't like the look, then you might want to just make the plug flush with the end of the horn.

A shiney finish is acheived by sanding with progessively finer grades of sandpaper and then polishing with a buffing wheel and buffing compound.

Just reverse the process. Try sanding with some sandpaper that is maybe 400 grit. That should dull the horn. If it is too dull for you then proceed to sand with 600 grit then 800 grit then etc. etc. until you find a finish you like.

Old horns appear to have only a scraped finish which you can duplicate by scrapeing the horn with a sharp knife.

Randy Hedden

 

[bob308]

i have been reading the horn rework and am gettting ready to do it to my cheapie. but firt it is not tight around the plug. how would you seal the plug? the plug is hailed in with 6 brass nails.

 

[soggy]

i have been reading the horn rework and am gettting ready to do it to my cheapie. but firt it is not tight around the plug. how would you seal the plug? the plug is hailed in with 6 brass nails.

:v I'm not trying hi-jack this thread, but this is what I'd do if it were me.
Get some bees wax, melt it down to liquid form, then pour it into the horn using a small funnel, and quickly swirl it around before it hardens. I believe this is standard procedure by most horn makers.
Others may have different methods, but I have found this works for me.
Soggy

 

[Harddog]

i have been reading the horn rework and am gettting ready to do it to my cheapie. but firt it is not tight around the plug. how would you seal the plug? the plug is hailed in with 6 brass nails.

Bob,

just get some beeswax and work it in the area between the ******** and the horn from the outside of the horn. Take a small piece of beeswax and roll it between you fingers to make it soft and into a tiny roll of beeswax. Use you fingers to force this roll of beeswax down into the crack between the ******** and the horn. Work beeswax in until you can't get anymore to go into the crack. Then lightly blow or suck on the spout of the horn and see if the horn still leaks air. If it does then apply more beeswax and try for leaks again. THe beeswax will seal the horn and make it airtight for years. Polish and buff any beeswax on the surface of the ******** with a piece of cloth to spread any excess beeswax across the surface of the ********.

Randy Hedden

 

[paulvallandigham]

YOu might try making an replacement plug that is snugger in fit. You can also drill more holes, and use more than 6 brads or tacks, or drill rod to hold the plug in place. I like to drill all the holes, and fit the tacks, then remove the plug until final finishing, and then run a bead of epoxy glue around the edge of the plug, and the inside of the horn, so that the surfaces are well mated together. I use the holes to align the plug in the horn, and then hammer the tacks in as more of a decoration than something that actually hold the plug in the horn. The glue does that. When it dries, I blow into the horn's mouth to see if there are any air leaks. If they exist at all, and are small, you can often seal them with a dab of epoxy glue. Otherwise, pour in hot beeswax and swirl it around the outside of the bottom plug, so it fills in the holes, permanently.

 

[bob308]

thanks that was one of the things i had in mind if it works it is easy to.

the second idea is the other one i was looking at refitting the base plug.

 

[tmdreb]

Then lightly blow or suck on the spout of the horn and see if the horn still leaks air.

Randy,

I can't thank you (and the others who posted) enough for the advice you've given me. I've gone nuts with the file already, and though I have a lot of other things I need to be working on keep finding myself out in the garage every evening filing away on both the horn and ********.

I would have to advise that when working with the cheap horns like I've got, not to suck on the horn or blow in a way that might stir up all the dust on the inside. Mine is apparently full of fine dust from where the spout was drilled into the tip, and it loves to fly out at the slightest provocation and take up residence in my respiratory tract or eyes.

I'm not buying another horn like this one. I just don't want it to go to waste, and I figure if nothing else, it's great practice for the next project.

Thanks again.

 

[paulvallandigham]

Maybe you are more in a rush to complete a horn than I have ever been, but I always wash the horn out to get rid of dust, chips, and filings, on the inside of the horn before completing the construction by putting the base plug into the horn. You should not have any trouble blowing into the horn after its cleaned and dried.

 

[tmdreb]

I tried washing it out, but didn't get much of a result. Also, it was supposed to be finished when I bought it. I had no idea all that fine dust was in there.