Making a horn box

[Ahtuwisae]

Just another way of doing things. I thought this would be a good post to follow up Eric's posting on his boxes.  I will try to make sense out the photos as I go

measure both widths of the large end and average the two.  This is your first caliper width for the mandrel. Measure up the mandrel with the calipers and make a mark.










Now measure the length to the shortest end and mark your mandrel.




Now repeat the measurement for the small end and set your calipers for the average. Now you are ready to turn the mandrel.  start by turning the mandrel at the large and small ends at your marks to the measurements you took.  use the calipers to measure.  Now, turn the mandrel from the large end to the small end with an even taper using a gouge.  Then smooth the whole mandrel to meet the taper.








Smooth the mandrel out with sandpaper or a sanding pad.


Now I mark my lathe and the mandrel with a sharpie so when i put it back in after pressing on the horn it has the same alignment.  You can do this at both ends.


Now prep the mandrel, horn and lard for heating


the lard should be between 325 and 350 degrees.  Remember the temperature will drop several degrees when you insert the horn.


Put the horn in the lard until you see the telltale bubbles rising up.  be careful not to scorch the horn. A good way to make sure this does not happen is 10-15 seconds in and 10-15 seconds out..about three dips should do it depending on the thickness of the horn.  it takes some practice.  The horn should be very flexible and almost rubbery before you press it on the mandrel.


Wearing gloves, push it on to the mandrel until it stops


I then turn it upright in the vise and hit it with a ball peen or heavy rubber mallet until both ends of the horn are formed to the mandrel.  If your measurements and turning was accurate there will be no gaps between the horn and the mandrel and it will be relatively close to your marks.

Now, remount the mandrel in the lathe using the marks you made on the head and tail stock to line it up. (yes it is a different piece of horn...I cracked the first one...lesson...make sure it is heated enough and you do not hit it TOO hard!!)


Square the ends with a parting tool, and turn the horn smooth with a gouge and a flat scraper.






Now you can remove it from the mandrel and you should have a nice round piece of horn.


On to turning the inside!!  Some will tell you to use a cup chuck but with boxes they should remain rigid enough to use a check to mount them.  I wrap a piece of leather around the outside so the jaws do not cut into the horn should it slip


i use a modified flat scraper to turn the inside.  it is nice as you can face the end of the horn and it is rigid enough to turn the length of the inside without chatter.




You can either turn halfway and then turn it around in the check or cut the whole depth.  i chose here to cut the entire depth






Polish up with some sandpaper or  fine scotch-brite and finish with 0000 steel wool for a nice satin finish.


And there you have it....turning the ends will follow later ans well as with the cabochon for the lid.

[Tim Crosby]

 Great job on the tutorial John, I'm sure it clears it up for a lot of folks. In a week or so I will move it over to the Tutorials forum.

   Tim C.

[cjarrett]

Great tutorial! Thanks.

[LURCHWV@BJS]

This really answered alot of my questions.  I made a mandrel today and played around   

  Thanx a million

   Rich