Suggestions on pewter

I'm trying to build a powder horn with a poured pewter spout. I've experimented with pouring pewter before but I can't figure out how to pour the spout onto the horn tip. Making a round, tapered mould that would match the contour of the horn tip, has proven difficult. If I pour it squared off, without the taper, there will be a lot of filing, sanding to do.

If any of y'all has done this before and has a suggestion I'd appreciate it. GW

I've done something similar. I use beeswax to make a positive copy of the shape I want. Beeswax is easy to carve to shape. Then I remove the beeswax, set it into a small box and pour plaster around it so it comes half way round the side of the beeswax. Then I paint some dish washing liquid soap on the plaster once it sets up and pour more plaster on top so it covers the beeswax. Then I place the whole thing in the oven so the wax melts out leaving a void. Then I pour pewter into the void, let it set then crack the mold open (the liquid soap helps to split the plaster into two pieces) and out pops the pewter casting. Then it's just a case of polishing and finishing.

If done carefully, the mold can be used many times.

I find the best plaster to use is hardwall plaster. It's the kind they use in schools and hospitals so it'll take the knocks of chairs and beds being slammed into them, so it lasts longer and is much tougher for hot metal moulding. This technique also works for lead, silver and brass casting.

Eric

I don't know what I'm talkin' about at all here, but sometimes that's a good thing. :haha:

How about rawhide? If you wet a piece and sewed it around a horn tip, waited until it dried and shrunk to fit, then pulled it off, would that work for a mould?
You could stick it on the other horn, cut off the tip, and pour right in.

Just ramblin'. Like I said, I ain't got a clue about pewter...

Jethro,
I plan to pour the tip directly onto the end of the horn. Rawhide, or plaster as Eric suggested could be used as a mold. I'm just gonna have to try something on another piece and see what happens. I'm afraid that iffin I pour it and it doesn't turn out like I imagined, it'll be tough to get it off the horn tip. There's a bunch of holes and grooves cut into the tip to keep the pewter in place.

Thanks guys for the ideas. I'll let ya know how it turns out. GW