Steps In Making A Philly Style Screw Tip/My Way That Is: FINISHED

[Tim Crosby]

Here are some shots of the making of a Philadelphia style screw tip horn.

The firsts show the starting point.
Next was to measure and cut the tip.
Drilling into the body cavity
And enlarging that hole to 17/32nds for taping. I put a stop on the bit to keep it from chasing the ¼” hole any farther than I wanted it to. Also putting a hose clamp around the horn at this point will help keep it from splitting, leave it on for the next step also, you may have to fit the clamp to keep it from sliding.   
Here you can see a 5/8-11 bolt screwed in. Didn’t get pics of tapping but it is pretty straight forward, just go slow, maybe ½ to ¾ turn and back out a qtr or so, I used Dr. Jackson’s Hide Rejuvenator as a lube.  The stuff works great on dry hands too.
Next up the collar, the start.
Rough shaped and ready to drill.  Above, where the bolt is screwed in, I shaped the very end of the horn down to about ¾”, just so it would almost fit in a ¾” hole. I used ¾, it could have been larger or smaller depending on the collar/tip size and shape.
Chucked up and drilled.
Here it just barely fits on the tip
The collar needs to be opened up so it fits the horn. Back in the chuck takes some off and then a finial fitting using transfer color. A tapered pipe reamer helps here. You may have to go back and forth to get it close. I wait until the tip is turned and final fit the collar and tip together.
It is close enough that it can go back in the chuck and get shaped.
Close here.
The area where the collar will be it taped off while the rest of the horn is roughed shaped.   
 
I hope this is understandable. Pt II tomorrow.

Tim C.

[Tim Crosby]

 I added three pic that I left out at the end of yesterday's post.


The tip cut longer than needed, drilled and mounted on a pen mandrel (PM)

Rough turned

The part that will be threaded, it is slightly longer than needed and tapered a bit to help get the die started. At this point it comes off the PM and I drill it for a 5/16-18 tap so I can screw a little jig in to help with the treading

The jig

The jig screwed in and ready to have the die started. I start the die by hand and then lock the die in a vice and use a pipe wrench to turn the tip into the die. Backwards I know but it works. Maybe ½ to ¾ turn, back off a qtr, keep the chips cleaned out and go slow. When it bottoms out turn the die over and run it back on slowly, be careful not to get it cross threaded, you may get another ½ to ¾ turn out of it. I take the die off and run a nut down on it a couple of times with a little bee’s wax as a lube. It kind of burnished things up a bit.

The finished job. You can see where the teeth from the pipe wrench scar up the tip but all that will be turned off.

Back on the lathe and almost finished. 

[Tim Crosby]

 This is a lot bigger than I thought it was going to be.

This shows the tip and collar final fitted to the horn

Next is the horn band for the base. At this point the base of the horn has not been cut, I know about where I want it but instead of cutting the base and trying to fit a band I find it easier to find a band that fit the general area and work from there.

This piece has been boiled to soften put on a cone, squared up and had the thickness evened out.

Here it is turned to shape and on the horn, Only a little pircr had to be trimmed off the body to get it to fit.

How things look at this point.

Here it has had a little color put on it to show and gouges or deep scratches, all the color will be scraped off before final coloring. The base has also been rounded with a sizer.

The chunk of Maple that will become the base.

Rough turned. The right side is turned to fit the horn, the left will be turned down so it will fit in the chuck. Once it is in the chuck it is hollowed out. Then turned around and finish turned.

Before color

After color and finish     

[Tim Crosby]

 And the finished  horn.  It is about 15” around the outside curve, the base is about 2 ½” and held in with four wooden pegs, they also hold the horn band on. The collar is held on with two wooden pegs and one leg of the staple.


 I know I left out a couple of pics but I hope over all it was understandable.

 Tim C

[Shovelbuck]

Thanks for the tutorial. Helped me understand them a lot!!!

[Kermit]

Several thousand words worth of pictures. Thank you!

[T.C.Albert]

Thats a beauty Tim....it turned out great. And I learned a whole bunch from the tutorial too. Thanks a million ...
TC

[BILL OKLAHOMA CITY]

Tim,
thank you for sharing!

[skillman]

Tim

Great tutorial and a super looking horn. Nice work!

Steve

[Pvt. Lon Grifle]

Thanks for a great explanation of the process.    Lon

[A.Merrill]

     Very nice horn, looks great. Excellent tutorial. Thanks Tim.    AL

[Ken G]

Tim,
I don't even make horns and I enjoyed the tutorial.  Thanks for taking the time to take the pictures and post the tutorial.  Great job.
Cheers,
Ken

[A.Merrill]

    What kind of stain did you use on the horn? Once again, great job.    AL

[T.C.Albert]

This horn is great !...I needed a Philly tip  horn made for a bench copied pouch set Im attempting, and asked Tim if he would work with me and do the horn...he agreed to do it , and I just got it in the mail today. All I can say is WOW...it truly is a work of art...thanks Tim.
TC

[Tim Crosby]

    What kind of stain did you use on the horn? Once again, great job.    AL

 That is kind of a catch all of old dyes. The base is Brown dye.

Tim C.

[Tim Crosby]

This horn is great !...I needed a Philly tip  horn made for a bench copied pouch set Im attempting, and asked Tim if he would work with me and do the horn...he agreed to do it , and I just got it in the mail today. All I can say is WOW...it truly is a work of art...thanks Tim.
TC

 Thanks Tim and Everyone else. I hope it helps.

 Tim C.

[Kermit]

Wow. Thanks for doing this.

[Carl Dumke]

Tim,
Thanks for sharing--hope my request did not cause too much pain!  Waiting to find the right horn to make my attempt--beaut of a Philly horn!

[hanshi]

That is a beautifully done horn; well beyond my expertise.  I don't have a drill press or lathe (not that it would make any difference) but I did make screw tip plugs for two horns.  I used short sections of bolts and plugs, one with a ball end, the other with a prime measure plug.  One screws into a threaded antler plug tjat can be easily removed for filling.  The other screws directly into the horn tip which is tapped.