• This community needs YOUR help today. We rely 100% on Supporting Memberships to fund our efforts. With the ever increasing fees of everything, we need help. We need more Supporting Members, today. Please invest back into this community. I will ship a few decals too in addition to all the account perks you get.



    Sign up here: https://www.muzzleloadingforum.com/account/upgrades

Making a Powder Horn (Part 1)

Muzzleloading Forum

Help Support Muzzleloading Forum:

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.
Joined
Nov 11, 2011
Messages
4,364
Reaction score
10,887
Location
Surry County, North Carolina
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.
 

Attachments

  • HC 1.jpg
    HC 1.jpg
    146.3 KB · Views: 5
  • HC 2.jpg
    HC 2.jpg
    124.7 KB · Views: 0
Last edited:
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.
 

Attachments

  • HC 3.jpg
    HC 3.jpg
    136.4 KB · Views: 0
  • HC 4.jpg
    HC 4.jpg
    126.9 KB · Views: 0
  • HC 5.jpg
    HC 5.jpg
    137.9 KB · Views: 0
  • HC 6.jpg
    HC 6.jpg
    148.9 KB · Views: 0
  • HC 7.jpg
    HC 7.jpg
    147.2 KB · Views: 0
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.
 

Attachments

  • HC 8.jpg
    HC 8.jpg
    148.5 KB · Views: 0
  • HC 9.jpg
    HC 9.jpg
    164.8 KB · Views: 0
  • HC 10.jpg
    HC 10.jpg
    84.9 KB · Views: 0
  • HC 10a.jpg
    HC 10a.jpg
    158.8 KB · Views: 0
  • HC 11.jpg
    HC 11.jpg
    152.5 KB · Views: 0
  • HC 12.jpg
    HC 12.jpg
    105.1 KB · Views: 0
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).
 

Attachments

  • HC 13.jpg
    HC 13.jpg
    97 KB · Views: 0
  • HC 14.jpg
    HC 14.jpg
    134.4 KB · Views: 0
  • HC 15.jpg
    HC 15.jpg
    163 KB · Views: 0
  • HC 16.jpg
    HC 16.jpg
    188 KB · Views: 0
  • HC 17.jpg
    HC 17.jpg
    214.3 KB · Views: 0
  • HC 18.jpg
    HC 18.jpg
    212.7 KB · Views: 0
  • HC 19.jpg
    HC 19.jpg
    187.2 KB · Views: 0
  • HC 20.jpg
    HC 20.jpg
    196 KB · Views: 0
  • HC 21.jpg
    HC 21.jpg
    188 KB · Views: 0
Last edited:
Thanks for posting this up mate, I've been meaning to make my own horn someday when I come into a horn.
 
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!
 
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!:D
thank you for the response!
 
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
 
Back
Top