Bovine Cow Horn-Anyone ever tried workin' this stuff?

[whitebuffalo58]

A few years ago, my bro-n-law gave me a couple of feedsacks full of cow horn. Most of these have some amazing colors in them and polish up beautifully. I've slabbed up pieces for small folders out of the tips, which are solid usually for the first 3" or so. But, the rest of the horn is too thin to use as is and in many cases has the best color. I've been told that the thinner parts can be cut into larger pieces and boiled, softened and clamped flat. Then, laminated together to make thicker pieces. I've also been told, that the boiling process smells really bad and that wives would probably prefer you do it outside.
I was just wondering if anyone here had tried it, and how it worked out for 'em? From what i've seen of the insides of the horn, seems like the pieces would require atleast some amount of sanding, after flatening them. To me, that would be a bit tricky.
I've also thought that maybe the flatened pieces could be laminated to a sub-straight material such as micarta or other composite and just use the horn as a top layer.
I sure would like to figure out a way to use this stuff, I think it could produce some pretty amazing handles. Here's just one example of the ones I have. There are colors ranging from pure white to pure black. Streaked to mottled and every color and pattern in between.

Thanks for any input.
WB

[jerryd6818]

Try it. What do you have to lose but time? I think if you laminated it onto a substrate, the substrate material would show around the edges of the finished product. Not good unless that was the look you're going for. I'm thinkin' three or so layers bonded with two part epoxy should do the trick.

As you already know it's hard as a rock. Like deer antlers, the horn stinks to high heaven when you cut it with a band saw so I can't imagine it smells too sweet when you boil it (maybe not a full boil). It's the same stuff as hair ya know (Keratin).

[muskrat man]

It can be done, to an extent, the boiling and flattening, not fully flattening it is the key to keep it thick enough. Send me a horn or two and I'll do a tutorial

[whitebuffalo58]

Jerry, the solid pieces i've worked with smell worse then Buffalo horn. That's hard to imagine, but true. It's one of those smells that linger in your nostrils all day and will almost make ya sick to your stomach. I was really hoping what I was told about the boiling process was just fable, but you're probably right, better consider firing up the Turkey cooker outside.
I've found cow horn to be just a tad softer then stag, but still tough as nails. It cuts, drills, sands and polishes up great. Just haven't figured out a way to get bigger pieces yet.
Kaleb, when you say not to flatten all the way, what would you do, fill the hollow with epoxy or something like that? That actually sounds like it could work. Just have to judge how much crown to leave to match the thickness of the bolsters.
As far as sendin' ya some, if you're serious, that's a definite can do. Just PM your mailing address and i'd be more then happy to send you a couple. I have several and pretty sure I can get more if I want it.
Thanks guys!
WB

[jerryd6818]

better consider firing up the Turkey cooker outside.

Thanks guys!
WB

Maybe you should consider getting yourself an old gallon paint can and try using that. Be a shame to ruin a perfectly good Turkey cooker. You would hate yourself (not to mention how your wife would feel about that).

[whitebuffalo58]

Yes sir, I meant just the burner part. I've got an old cast iron dutch oven I thought I might use for the boiling. I agree, i'm a happily married man and prefer to stay that way!
WB

[Joe Dirt]

I've got some of those horns also... I'm in the same dilemma as how to get a usable piece of the thin colorful portions.

PLEASE, either you WB or Muskrat Man, post a tutorial!

PS if anyone WANTS to know what it smells like - the next time you trim your fingernails, take a clipping and light a match to it

..... Joe

[whitebuffalo58]

Hey Joe, good to see ya back!
Somehow, someone's gonna figure out a way to make this stuff work. Trick will be, to figure out a way that's not so labor intensive that it's not worth the effort.

WB

[muskrat man]

Kaleb, when you say not to flatten all the way, what would you do, fill the hollow with epoxy or something like that? That actually sounds like it could work. Just have to judge how much crown to leave to match the thickness of the bolsters.
As far as sendin' ya some, if you're serious, that's a definite can do. Just PM your mailing address and i'd be more then happy to send you a couple. I have several and pretty sure I can get more if I want it.
Thanks guys!
WB

You could do that, though I've seen a variety of Italian knives with small hollows inside the handles. Anyway, yeah if you don't care to send me one I'll do some show and tell. I have done some cow hoof and it makes a very unique handle.

[whitebuffalo58]

No problem MM, just tell me where to send it and it'll be on it's way.

WB

[muskrat man]

I got the horn yesterday. I'm gonna clean up the shop some today and try to get the pictorial up this weekend sometime.

[whitebuffalo58]

Glad it made it, hope I picked ya out a couple of decent ones to work with. Can't wait to see the results.

WB

[jerryd6818]

A few articles on working with horn. The first one is the shortest.

• http://www.knifeknowhow.com/working_with_horn.htm
• http://www.personal.utulsa.edu/~marc-ca ... horng.html
• http://www.florilegium.org/files/CRAFTS ... mphlet.pdf

[whitebuffalo58]

Hmmm...interesting articles Jerry. Sounds like the thin stuff might be a bit too unstable for me. Just how warm would be enough to start it to curling back? Body heat? Never would have imagined the stuff being able to burn up in a pan of boiling water either.
Oh well, if anyone can figure out a good way to use it, Kaleb can. Just have to see what all he comes up with.

WB

[jerryd6818]

You have plenty of horns, WB. Play with it (maybe outside so you don't have to find a new place to live like the dog house ) Cut up one of those horns into sample size pieces and experiment. See what it does. That business of burning up in boiling water sounds a little fishy to me but what do I know, I've never messed with the stuff. There's no experience like practical experience.

[whitebuffalo58]

Yep Jerry, it's one of those things that's been on the list for about 5 or 6 years now. I have used a few of the tips to slab up for small pen knives, but they're usually pretty much one color and don't have the character the shell area of the horn does.
I will get around to using it one way or another. But not today, the weather here ain't fit for man nor beast.

WB

[Joe Dirt]

Very interesting articles, Jerry! I learned a LOT just by reading them.

It got me thinking about that seldom used turkey deep fryer on the back porch.... might just keep me out of that dog house.

All the horn handle knives I have are made from solid pieces. I'm with WB on that stuff turning back to it's original form within 3 years.
Not sure if it would be worth the effort.

...... Joe

[whitebuffalo58]

I got to wondering if laminating layers together in alternate directions (like plywood) might make a slab that's not just thicker, but more stable. Only thing though, that rubbery epoxy stuff they talked about in the one article, I don't think I have any of that.

WB

[orvet]

I didn't read the article, but a good of industrial strength rubber cement might be a good adhesive. Have you tried Pliobond? I can get it at my local Ace Hardware store. It is great where you need a flexible bond.

[Joe Dirt]

Wonder how many layers it would take to achieve a usable thickness?
Rather than a bidirectional laminate, a multiple random directional laminate would be even stronger.
May get the best results using the thinnest layers possible to make a thick piece.

I don't know about using a "flexible" epoxy. I would be very tempted to use a hard setting type in lamination.

..... Joe

[muskrat man]

Wonder how many layers it would take to achieve a usable thickness?
Rather than a bidirectional laminate, a multiple random directional laminate would be even stronger.
May get the best results using the thinnest layers possible to make a thick piece.

I don't know about using a "flexible" epoxy. I would be very tempted to use a hard setting type in lamination.

..... Joe

2-3 layers would do for most knives.

Sorry men, was planning on doing the tutorial today but got caught up with prior obligations. (like rehandling a half dozen GECs for Monk, among other things). Tomorrow will probably be tied up to but I'll definitely get it done this week for sure!

[muskrat man]

How-To now posted in the tutorial section