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Building a Powder Horn

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Here's what I did (I am no great horn maker mind you).
I made a wooden cone as a mold to make the horn a concentric circle heated the horn with oil and shoved the cone in. Then I made the plug. I have a crappy lathe but it's a lot of work to setup, so I did it by hand. I started with a 3/8" step in the plug to go inside the horn. I cut that with a Japanese pull saw and chisel. I sanded the horn rim flat on a piece of sandpaper on a table and very carefully tapered and reduced the insert part of the plug until it fit.
I had to trim the edges of the step with the chisel until it fit perfectly. ( I made a pencil mark on both to keep them lined up because the horn still wasn't a perfect circle). Once I had that, I traced around the horn into the plug. Removed the plug, trimmed down to the line, and shaped it. When. I was happy I glued and tacked it in place with brass brads.
After all that the wood was still just slightly larger than the horn. I used a steel scraper to make it even with the horn, but probably would have been fine like it was. Not a 5 min job, it took a full evening. The lathe would have definitely been faster.
I also used The book by Sibley to supplement tutorial by PathfinderNC.
What I learned and will do differently next time is the boiling or heating to make the base fit a round base plug. I tried to fit an irregular space with lots of sanding. It is airtight now but it took more effort than necessary and the cosmetic results, are, well, rustic at best.
I can say that drilling the spout was not a problem for the first timer.
I like it, based on other viewings of authentic 1700's horns and repro amateur products, it is very good. It was after all, an personal expression of someones art and story telling. You got me interested, now I want more!
That's a really nice looking little horn, @Kev308 . I especially like the carving around the spout. Taking off material to slim it down while leaving the "collar" as you did takes time, but it makes a much more graceful and visually balanced horn than one with a really thick neck.

Strong work, my friend.

Notchy Bob
Thanks Notchy Bob! I appreciate the compliment
Hey Lucky, my powderhorn kit and horn roll primer parts arrived today...looking great!

For those in the know, does anyone have good reference materials for early 1800's horns carried in the western territories. I'm not seeing much art depicting NWC or HBC folks and their horns. Best I can figure, based on First Nations and Canadian War Museum pieces, is that the base plug should be either flat and flush or sticking out about 1/2" rounded down to the horn (i.e. a flat top dome). If anyone has any other info, please let me know :)

My horn is going to be fairly plain (or at least that is the plan at this point) and I'll likely dye my stopper and curly maple base plug to match what I did with my Colonial.

I also have a black horn roll and priming spout....I'll drill the roll and thin it on the spout end to make a little primer to replace my brass one that split (and to "blend in" better....I know priming horns and flasks really weren't a "thing" out my way for quite some time after the general period I'm going for).