Thread: Lessons Learned: Making Burl or Thin Horn Scales

I've learned a few things lately while making Burl and thin Horn scales and thought I would share with the workshop thread.

I had some beautiful burl, which had been stabilized, break using pressure that shouldn't have been a problem. I've also found a lot of horn that warps when the scales become thin.

The same solution works very nicely for both. I use a .030 inch G10 liner. Here are the highlights:

• Always remember the toxicity of G10 dust. A proper respirator with correct filters is a must. Don't cut or sand G10 indoors.
• G10 is available in many colors, including one that is somewhat, though not completely, transparent.
• Two part epoxy is the best adhesive.
• There are two types of two part epoxy that I know of. The quick set and the somewhat longer set. I don't recommend the quick set. Gorilla Glue's two part epoxy is the quick set.
• After research, I settled on West Marine's epoxy. G-Flex is great, though doesn't dry clear, thus it needs to be dyed. I use West #105 epoxy and #207 hardener for a clear finish, though it isn't as strong as G-Flex.
• Be very careful about bubbles, which you can see through thin horn and other materials. I dye the epoxy in a color that enhances the transparency of the scale material I'm working with.

From this list, the most important lessons are to avoid 5 Minute two part epoxy and watch the bubbles very closely if the scale material has any amount of translucency.

Burl breaks easy. Stabilization makes it water proof but does not improve tensile strength at all. Backing burl with something like thin acrylic or G10 fixes the problem.

Great advice! I've settled onto very thin copper or bronze sheets as liners for the thin stuff. It'll crinkle a bit as it finds it's shape but it's all on the inside of the scales so not obvious. But G10 is a better looking solution.

Not sure why I typed bronze... should read brass - I think. Damn now I have to go look later.

Originally Posted by AirColorado

Great advice! I've settled onto very thin copper or bronze sheets as liners for the thin stuff. It'll crinkle a bit as it finds it's shape but it's all on the inside of the scales so not obvious. But G10 is a better looking solution.

I'll have to try brass and acrylic.

There are many good things about G10, though the toxicity of the dust concerns me. Also, G10 is hard on machinery, sanding belts, blades, etc...