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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 it down from 3/8 to 1/8 thick. My "shop" consists of a belt sander, a scroll saw and a Dremel drill press thingy. How can I split the 3/8" pieces into halves? I could do it with the scroll saw, I guess, but there's no way it would be a straight cut. What's the right tool for this job?
Band saw with an accurate fence,scroll saw would be a mistake IMO
if there is a cabinet or custom wood shop near by you might be able to get it slip for little or nothing. It's amazing what you can get for asking.
I have split wood with a scroll saw and it wasn't all that fun. I used a straight block of wood and some C-clamps to make a fence and even then the cuts weren't all that straight since how the blade moves doesn't give you alot of control when trying to split something so thin and tall. More hassle than anything. That is when I decided to get a bandsaw. Never tried to split horn so not sure how it would cut on a scroll saw with how it is layered. Wanting to see what others say.
Even when you cut blanks down yourself it is usual to leave a little material to sand away any striations, etc from the cut and to gradually refine the grits to make it shiny.
I would treat it like that - double-sided tape holding the blanks side-by-side on a flat bit of wood passed over your belt sander. Coarse grit to start with of course, and a face mask - it's going to get dusty and smelly!
Ideally, a decent rasp to even out the sanding and making sure the blanks were square from end to end would be nice.
Regards,
Neil
I managed it by making a jig and cutting the blank down using a fine Japanese pullsaw - it was fiddly but it worked in the end.
What Christel said.
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 it). The blade broke and now the saw is clacking away like made. I tried adjusting the tighten/loosen knob, but it doesn't help. Anyone else dealt with this?
Thanks again.
A power tool is not always the answer. I'm as guilty as the next guy on this one.Quote:
Originally Posted by Christel
Sometimes a hand tool is the right tool for the job. You are not making a thousand of these...
i have a bandsaw to use but i still prefer to rip scales by hand. i scribe or draw a line down the center all the way around, cut down about an inch at an angle and then flip the piece (still cutting from the same end) and keep doing this 'till done. this helps keep it accurate as well as making it a little easier since my saw isn't cutting the whole width of the piece all the way down.
I use the belt sander. What ever you do keep it cool or you will make a banana shaped object :<0)
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.
I use a shop vac to eliminate dust problems. A lot of tools come with dust collecting hook up. Although I would still wear a mask or at least a bandana or something to keep that out of your lungs. Helps with the stink too :<0)
Rough grit, tub of water, and dry the horn unless your belt is okay with water.
Quote:
Originally Posted by Christel
I like this idea a whole bunch. If you find the time could you post a pic of the jig you put together? I have some wood and some horn that I would like to try it on.
I take the stock and put it in the middle of 2 thicker pieces of wood so it will stand square on the long end. I put a couple strong clamps on the wood holding the stock in the center and run it slowly through the scroll saw to "split" it. The scroll saw blade is very thin so there is not much waste, just be sure the tension on the blade is tight to keep it from wandering.
I have done this with horn and expensive hardwood.
Mastershake, that's sounds very do-able. Just wondering, what kind of blade do you use to cut the horn?
Are you holding the stock in a vice when you do this?Quote:
Originally Posted by tintin
Whatever method, please use a very coarse blade with a good set to clear the cut of dust.
~Richard
Sure thing!Quote:
Originally Posted by randydance062449
It's nothing special, just a flat piece of plywood and two guides that are fixed with double sided sticky tape. Clamp the blank down and use the guides to cut - not hugely fast but it's very cheap and does the job. With a very fine pull-saw, you can just lay it flat on the guides and pull with one hand, while the other presses and holds it flat to the guides.
http://i16.photobucket.com/albums/b2...ps2fa00e05.jpg
http://i16.photobucket.com/albums/b2...ps373638ed.jpg
I've cut down 8 honey horn blanks with this set-up so far and I can't complain. Hope this was what you were hoping for - if not, just ask and I'll see what I can do. :)
Thanks for the pics and the explanation. I had imagined the horn being sandwiched between the 2 pieces vertically and a vertical cut being made. Now I see that the guides are actually horizontal thickness gages and the saw cut is horizontal.
Now see what you did? you gave me more ideas! :)
There would be nothing stopping you from clamping such a jig in a vice and cutting vertically - the advantage of having it horizontal is that you can apply pressure straight down onto the blade of the saw and make sure that it stays straight. I'm sure there are other ways to swing the proverbial cat and I'm glad that I gave you some ideas. :)
I like to use a plywood scroll saw blade or a medium tooth blade. I don't use a fine tooth I feel it creates too much heat and burnt horn smells awful!Quote:
Originally Posted by moostashio