Just some tips and tricks for making a horn yourself. This method use all compound angles to make a radial horn. 17" wide X 5 1/2" tall, 7" deep with the flange. 430mm x 140 x 175.
|
|
|
|
|
|
|
|
|
|
Top and bottom are planed to the angle using a planer and wedge under one side to make the angle |
|
|
|
|
|
|
|
|
|
|
|
|
Sides are roughed with a band saw. A tennon jig works great too if you have enough depth of cut. |
|
|
|
|
|
|
|
|
|
|
|
|
precise angles are then flycut in a bridgeport mill. |
|
|
|
|
|
|
|
|
|
|
|
|
|
The compound angle for the sides is done with a taper jig on the table saw. The back angles are set with blade angle.
The taper angle doubles and the piece is flipped over for the two sides to match. |
|
|
|
|
|
|
|
|
|
|
|
|
Blind screws for the top. Make a set up in a drill press. It will help with the counter bores for the deep pockets.
this one is just a photo. |
|
|
|
|
|
|
|
|
|
|
|
|
The screw holes will need to be counter bored to the right depth and screw so not to break through the top when screwed in. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Sand everything before assembly |
|
|
|
|
|
|
|
|
|
|
|
|
Top screws onto the sides, through the sides. Pre drill pilot holes and a little wax or soap on the srew helps out. |
|
|
|
|
|
|
|
|
|
|
|
|
Bottom now screwed to the sides. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Blade angle set to main angle. Trim the face so everything is now flat. |
|
|
|
|
|
|
|
|
|
|
|
|
|
The blade will need to be angled. You will also have hold the horn tight. The srcews that hold the sacrafice wood on my miter gauge poke through the wood 1/16" This lets the miter gauge Spike the horn to hold it. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Just get a close skim with the last cuts. Sand the rest. |
|
|
|
|
|
|
|
|
|
|
|
|
Make sure the fence is high enough to support the face while you hold the horn up off the table and on the fence for this cut. |
|
|
|
|
|
|
|
|
|
|
|
|
This project envolves all kinds of FUN! Use a DA for the tougher spots. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
You can blend the angles into each other when you pre sand the sides. This is a mock assembly so you can see the angles very pronounced. |
|
|
|
|
|
|
|
|
|
|
|
|
Use a Mill to locate and drill all the mounting holes for the flange and Center hole. Its best to make your 1" center hole and locate from there. Brass thread inserts are screwed into the horn for the stainless flange studs |
|
|
|
|
|
|
|
|
|
|
|
|
|
More sanding. spray, sand, spray, sand, sand..... |
|
|
|
|
|
|
|
|
|
|
|
|
The beauty of figured hardwoods. |
|
|
|
|
|
|
|
|
|
|
|
|
Aluminum flange mounts for Two X 3" and Three X 2 1/4.
These are engineered to maintain flat response and provide an attractive and secure mount. |
|
|
|
|
|
|
|
|
|
|
|
|
|
Stainless Steel Hardware.
O-rings for gaskets. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A few changes for a better sound and a bolder appearance. |
|
|
|
|
|
|
|
|
|
|
|
|
A few coats of Laquer, waiting a rub down. |
|
|
|
|
|
|
|
|
|
|
|
|
Final design with new throat and flange. |
|
|
|
|
|
|
|
|
|
|
|
First coat with a flange test. |
|
|
|
|
|
|
|
|
|
Since there is not really a right or wrong way to construct. Use your imagination and make the best of the tools and equipment you have. Think safe, Let the tool do the work, and be safe.
Thanks for looking in.
HOME
