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Thanks Oz.
I'd really liked to keep the original scales, but with celluloid started to shrink I just didn't want to take any chances. Too bad :(

24. Sanding the wedge flush to the scales...carefully....then hand sanding and polishing.

http://i1212.photobucket.com/albums/cc450/Zephyr550/Restores/Toledo36_zps97bbf3db.jpg...

20. Making the wedge. I'm using bone for this one, here I make the "V" shape using the belt sander.

http://i1212.photobucket.com/albums/cc450/Zephyr550/Restores/Toledo29_zpsb19a8ec5.jpg

21....

16. Main shape is ready, here I change to a 180 grit belt for the final thinning and shaping.

http://i1212.photobucket.com/albums/cc450/Zephyr550/Restores/Toledo22_zps8ba1e208.jpg

17. Finished...

http://i1212.photobucket.com/albums/cc450/Zephyr550/Restores/Toledo15_zpsbaf5b609.jpg

11. Attaching the desing to the horn with double sided tape.
...

6. Blade finished.

http://i1212.photobucket.com/albums/cc450/Zephyr550/Restores/Toledo08_zps396e503d.jpg

7. Then to making sales. This is the horn I had picked out for this one, it's not very...

I've been thinking about doing this for a while, but knowing it would take a ot of time I've been postponing it over and over again, but this weekend I finally decided to go for it, so here is a "How...