Fitting a flat plug into a lipped horn

[DuncanvonYeast]

I have made some powder horns before, and I'm not bad at it, but I can't fit a flat plug into the sized base. I don't know if I have the taper steep enough or the plug is to long. the plug is made out of walnut and the sized base of the horn is 2 1/8 inch wide. I've never done a lip horn and need some advice. Thanks


                                                                        Duncan von Yeast

[Mikecooper]

I've made a few horns.  Only one had the lip with a flat base.  I'm not sure I understand what your question is though.

[Horner75]

I'm not sure that I understand your question, but the way I fit a lipped horn plug to the horn is measure inside of the horn with my calipers to where the lip will be and use that measurement for the plug.  Then cut the base lip and rest of the base area and the plug should be close to where you want it.  You only need a 1/2 - 3/4 inch of plug inside for your pins.

You can  also use a lathe and turn you a round base a little at a time smaller until you get the base plug positioned inside the horn where you want it.

And way three, is to turn your plug on the lathe similar to making a sizing form.  Tap it carefully into your rounded horn.  Mark with a pencil where the wood stops at the horn's edge.  Then pull out the plug and measure you desired length of the lip on the pencil line mark, say as an example 3/4" forward of that pencil line.  This line will show you where the plug will be flush with the outside of your horn base.  Then make one more pencil line to mark where your wood plug will end, say 1/2 inch.  Now it's just a matter of chucking in your lathe and cutting on your pencil marks and you have your near finished base plug.

[Mikecooper]

So you soften the horn and form it around a round form?  When I made one like that I kept it's natural form and fit the plug to it.   As I recall I fit the plug first making it small enough to fit down inside the horn then cut away the back part of the horn down to the surface of the plug leaving a tab on top.   For fitting the plug I glued a handle on to it so I could easily insert and remove it from the horn while fitting it.   

[Tim Crosby]

So you soften the horn and form it around a round form?  When I made one like that I kept it's natural form and fit the plug to it.   As I recall I fit the plug first making it small enough to fit down inside the horn then cut away the back part of the horn down to the surface of the plug leaving a tab on top.   For fitting the plug I glued a handle on to it so I could easily insert and remove it from the horn while fitting it.   

 Before you do anything make sure you horn is scrapped thin and shaped. The base kind of depends on what type horn you are making. If you want a round base you will have to heat it, oil/water/heat gun and then tap a sizer in.
 Do it before the lobe is cut to shape. Mark a line around the base on the sizer measure the diameter and turn a plug. If you don't have a lathe you can do the same thing, round the horn, square the end, stand it up on a piece of wood and draw around it, make a witness mark on the base, inside the circle and one on the horn. If you have a Band saw tilt the table to about 10 deg and saw out the circle (this will also work if you leave the base natural) If you do not have a band saw a coping saw will do. There is still hand work to do, if you have a disk sander set the table to once again 10 degrees or so. Start at the witness mark and sand around the circle, you will eventually take out your line, Once the plug starts to fit  take a soft lead pencil and shade the inside of the horn, keep the witness marks in line, press the wood in, remove and sand the pencil marks off the base. Takes some time, once the base is about half way in you can cut your lobe then continue to fit the base.
 I usually use 5/16-1/2" wood for the base with either leave about 1/8" sticking out of the horn, you can catch that edge with a knife and pop the base out. Once it is fitting like you want taper the top edge that is under the lobe, attach the base and work the 1/8" extra down to the horn. I like to make the base domed as some were.
 All of this can be done with hand tools, no coping saw, cut the edges off with a hand saw, no Disk sander, rasps and files 
 Hopefully this is not to confusing and helps.

  Tim C.   

[Horner75]

Note!..You want to use a horn that is evenly thick enough especially in the area of the lobe, so the lobe will not be subject to breaking off easily.

DON'T ASK ME HOW I KNOW!

[Tim Crosby]

Note!..You want to use a horn that is evenly thick enough especially in the area of the lobe, so the lobe will not be subject to breaking off easily.

DON'T ASK ME HOW I KNOW!

 When I used to do lobed horns I would pick a horn that was thicker in the area where the lobe would be. Leave that part thick and work the rest of the horn down.
 Just a thought.

 Tim C.

[DuncanvonYeast]

Thank you all for all of your advice I got the plug fit and epoxied today with the help from all of you It helped a 14 year old kid get this horn fixed.


                                                    Duncan von Yeast