How to Make & Carve a Flat Powder Horn

Soak the raw horn in water for five hours. Use a wood rasp to remove the hard, dry material that covers the horn. File down the horn until it is at the desired thickness. Thinly scraped horns hold the flattened shape better, but are less sturdy than thick horns.

Use a saw to remove 1/2 inch from the horn's tip. Starting with a 15/64 inch diameter bit, drill the spout hole directly in from the tip toward the center cavity of the horn. Using progressively larger bits, enlarge the hole to 9/32-inches in diameter.

Measure the inner circumference of the horn's base. On 1/2-inch pine board, draw the outline of the butt plug, an elongated oval shape, matching its perimeter to the horn's. A more elliptical plug creates a flatter shape. Cut out the shape with a jigsaw. Use sandpaper to smooth the edges and taper it into a plug shape.

Bring a pot of water to a boil and lower the heat until the water is simmering. Carefully place the horn in and allow it to boil gently -- checking occasionally -- for about one hour. Thicker horns require longer boiling times to become soft and pliable.

Carefully remove the horn from the water and place it on a thick piece of wood with the base exposed and 1 inch of horn protruding from the edge. Place another piece of wood above the horn and use two C-clamps to create an improvised wooden vise. Tighten the C-clamps on alternating sides, flattening the horn. When the horn's opening matches your plug, place the plug on a flat surface, lift the entire vise mechanism and carefully force the horn's opening down onto the plug. Push the plug until it goes no further. Adjust the clamps so the boards are parallel, then cover the whole apparatus with salt and let it dry for 24 hours.

Remove the clamps and inspect the horn. It should hold a flattened shape, with the plug firmly secured in the opening. Sand the end of the plug or the horn's base until the two pieces are flush. Trace an outline of the horn's base onto another piece of the 1/2 inch pine board and cut out the resulting shape. Mix a small amount of epoxy and cover the bottom of the horn's base and one side of the new piece, then join the pieces and let the epoxy set. Use files and sandpaper to smooth the outer plug and give it a rounded shape.

Perform any desired detailing to the exterior of the horn. Rings or grooves can be formed using small files, and a blade can be used to engrave or carve small details. Do not to carve too deeply into the horn. Use a file to remove any remaining inconsistencies before sanding smooth. Drill several small holes around the base of the horn into the wooden plug and install brass, iron or wooden pins.

Use steel wool to finish the outside, beginning with coarse wool and moving to fine to achieve a polished look. Apply some woodworking wax and buff to a shine. Light-colored horns can be decorated with scrimshaw. Two metal staples can be inserted in the side of the horn to act as strap hangers.

Create a spout plug from a hardwood dowel of slightly larger circumference than the hole drilled in Step 2. Use files and sandpaper to taper the end of the piece until it fits the hole. Plugs can be decorated with rings or spheres. Soak the plug in oil overnight to help reduce size changing from humidity.