Got another Great horn from Burnt yesterday and got started on it this morning. Greg asked about a build along so I'll give it a shot. I was going to post it all at one time but I think it would to big and a lot of work to sort out.
So here is the first part starting with the raw horn:
The first Two show the first cut and the tip marked to be cut
The next Two show the cut, the hole drilled and the start of the cut made with a 3'4" hole saw to made the portion that will be threaded.
Next shows tip after the thin wall left by the Hole saw has been filed away.
Getting ready to thread the tip I put a hose clamp on the exposed area to keep it from splitting in the next step.
The tip is being threaded so the Jig that will guide the Die can be screwed in.
The Jig and it screwed in.
The die is started and locked up in the vice to get it started, then the horn is turned all the way in. At this point it helps to turn the die around and run it back down, it will get 1 or 2 more threads or so.
A 5/8-11 NC nut turned on to the threads and down onto the horn..
A couple of notes:
1.The set has been taken out of the teeth on the hole saw. Cut only a 1/4" at a time or so, empty out
the dust from the hole and clean up the teeth, they will be clogged. If you don't heat will build up and
the horn will get scorched become brittle and not take the threads well.
2.The actual pouring hole was predrilled with a 1/4" bit. The Hole saw has a 1/4' pilot and the predrilled
hole will help guide.
3.File a slight taper/draft on the tip where the Jig hits the horn to help get the die started.
4.The Jig is a 5/8-aaNC tapped for a 5/16-18 bolt.
Next post will be the collar, that will screw onto the horn. Followed by the mouth piece, which will also screw into collar, finishing and a band at the Bell.
Tim C.
