Several years ago I decided to try my hand at making a powder horn. I planned on a plain working horn, nothing fancy. I didn't know any horn builders so for instruction I mainly used an article in Muzzleloader Magazine's Book of Buckskinning II. It is by Don Wright, and is really excellent for a beginner. I used a rough but dry horn, spent some time rasping and filing down the outer layers to proper thinness. Wright explains how to calculate the proper diameter of the base plug and that worked well. I turned the plug on the lathe. He explains how to measure and then drill the hole in the spout, and I managed that without drilling out and ruining the horn. From there on it was easier, fitted the base plug with beeswax and wooden pegs, whittled a stopper for the spout, then filed the shoulder and retainer rings for the carry strap. Sanded everything well, stained the base plug and its pegs, gave everything a good coat of brown wax and it was ready to go. It's a medium size, 12" horn. In all my reading I failed to pick up on the fact that cow horns come with right and left curves, so I wound up making a left-handed horn. I'm right-handed, but it is no problem because the curve isn't enough to make the spout stick out too far.
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