Making a Powder Horn (Part 1)

[PathfinderNC]

This is a basic primer for making a Powder Horn.

Part 1 is the basic build.
Part 2 (coming next) will be the decorating (scrimshawing) and finishing.

Hope this is interesting!

The first step (after selecting a horn) was to locate the end of the hollow at the point of the horn. I just use a metal wire to do that. Then, after marking that point, I add about an inch or so of length to make the cut. This will allow material for some tip shaping and enough room to hold the plug snugly.

I then use a 1/4" drill bit and aim it down the horn to where it will hit the tip of the inside cavity.

 

[PathfinderNC]

The next step is to draw the lines where I will make my transitions on the horn: the spout, collar and the neck (these may not be the actual terms but hey work for me). I use a small selection of rasps and files for this part.

 

[PathfinderNC]

When the front end is done, it’s time to address the base. I do two basic styles; a flat plug and a F&I (French & Indian War) style which has a ‘lobe’ extension past the wooden plug that the carry strap attaches to. (I find the flat base easier, but prefer the look of the lobed style).

I insert the base into a wooden block and use a hand saw to cut the line I made showing where the plug goes. (Cut proud and trim later)

I use the cut-off section as a template for the base plug. (I don’t round the bases of my horns but use the general shape of the horn). Then after tapering the plug slightly I will use a heat gun to get the horn very warm and malleable. It can blister and do nasty things if it gets too hot! Then I tap the base plug into the opening until it is where I want it. There will not be any gaps this way, and you can see where the horn expands to receive the wood.

 

[PathfinderNC]

Next locate the exact position of the base plug (measure or use a light if the horn is translucent enough to see) and mark where your dowel pins will go. 1/8” diameter is ample for the job. Apply some wood glue to them and drive them in and cut/sand them flush. At this point I will pour water onto the plug and allow it to swell the wood, which it will do, ensuring a really good fit.

I want to do some scalloping along the shoulder of the horn body. I draw some guide-lines and sketch the areas out that I will grind away. I use a Dremel tool that does a good job for this.

Then a little work to carve and fit the spout plug.

With the Powder Horn now basically built, it’s time to clean it up and start decorating it (if wanted). I will be doing some scrimshawing on this one, but have no idea what designs or theme I will do yet. That will be my next adventure with this horn (Part 2).

 

[TDM]

@PathfinderNC, very nice of you to provide this information for us. Thanks.

 

[Bushfire]

Thanks for posting this up mate, I've been meaning to make my own horn someday when I come into a horn.

 

[64Springer]

OK! Let's get this out of the way RIGHT NOW.

Sticky!

Let's make this thread a sticky. Stick a pin it already.

 

[2 shots]

who better to learn from.

 

[PathfinderNC]

OK! Let's get this out of the way RIGHT NOW.

Sticky!

Let's make this thread a sticky. Stick a pin it already.

Sorry, whats a sticky?

 

[garypl]

Great tutorial!

 

[64Springer]

Sorry, whats a sticky?

The moderators deeming your thread so AWESOME that they make it visible forever and ever by pinning it to the top of the thread list.

Best tutorial ever.

 

[50calBoone]

Awesome , You guys are so talented .

 

[Ranger94]

I have been looking for something like this for years!!!!! Many many thanks!!!!

 

[PathfinderNC]

I have been looking for something like this for years!!!!! Many many thanks!!!!

Glad it can be of help and good luck on your projects

 

[PathfinderNC]

The moderators deeming your thread so AWESOME that they make it visible forever and ever by pinning it to the top of the thread list.

Best tutorial ever.

Well thats very kind than you 64Springer. Hope I dont mess it up on part 2 though

 

[deerstalkert]

Pathfinder, how do you secure the horn while working on it? do you just free hand it or clamp it some how?
your work is an inspiration to all! artwork!

 

[PathfinderNC]

Pathfinder, how do you secure the horn while working on it? do you just free hand it or clamp it some how?
your work is an inspiration to all! artwork!

While working on the horn front, I keep it inserted on a steel bar through the spout hole. I file and rasp away with my right hand while holding it steady with my left. All the other work I just hold it while working on it. Glad you find it interesting!

 

[deerstalkert]

While working on the horn front, I keep it inserted in a steel bar through the spout hole. I file and rasp away with my right hand while holding it steady with my left. All the other work I just hold it while working on it. Glad you find it interesting!

would have to be blind or dead to not find it interesting! close, but not yet!
thank you for the response!

 

[Notchy Bob]

This is a great thread, @PathfinderNC !

Thank you for the time and effort you have put into posting it. I have learned quite a lot!

I do have a couple of questions... What heat gun do you recommend? I don't own one and in fact have never even used one, but it is becoming increasingly obvious that I could use a heat gun on a variety of projects. I could use some advice.

Also, can you recommend a good source for horns? I am familiar with Powder Horns & More, but would like some additional options, if possible.

I'm looking forward to the next installment. Scrimshaw techniques have always been a mystery to me.

Best regards,

Notchy Bob

 

[deertraks]

Thanks for sharing!