it is about 4 1/4" X 1 1/4" Once again a couple of the Pix are fuzzy but you get the idea.
As started
Tip cut & drilled
Shaping with draw knife, rasps and files were also used.
Saw cut to mark off tip, cut to the depth of a Coping saw blade.
Starting to shape the tip.
Horn cut off.
More Shaping.
Tracing around butt for plug.
Sitting on rough cut plug.
Tapering plug with files and rasps. A disk sander with the table tilted to about 10 degs really helps.
Use a "Witness" mark so the plug goes back in the same spot each time. Blacken the inside of the horn with a pencil, fit the plug, remove, take off the pencil marks until it almost fits.
Base fit.
Finished
Rounded plug. A wired brush, hand held, was used to age the plug.
Tim
PS: This one is for you Ray.
