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Mastershake, that's sounds very do-able. Just wondering, what kind of blade do you use to cut the horn?

Thanks for the help, guys. I will probably end up using the belt sander, too. However, it seems that it would take hours, and that the dust will be ridiculous.

Thanks guys, that helps. I think that, for me, using the belt sander will be the best option. There'll be horn dust everywhere.

I'm afraid I fried my scroll saw trying to cut the horn (not split...

I recently picked up two slabs of buffalo horn off eBay, 6 1/4 x 1 1/2 x 3/8. I'm looking forward to making a couple sets of scales from them, but I hate the idea of wasting so much material sanding...