HORN SPEAKERS #4: Marking and more Cutting

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Blog entry by stefang posted 12-18-2019 04:54 PM 1183 reads 1 time favorited 14 comments Add to Favorites Watch
« Part 3: Cutting the Wedges to fit the pattern Part 4 of HORN SPEAKERS series no next part

This is one of the two 90% finished horns being made.

Last time the square segments were marked out and cut into wedges according to the pattern.

Now it’s time to mark out for cutting in the scroll saw. This marking was for an earlier failed rendition and the inside diameters were enlarged for the final horns.

After cutting the the segment round and hollow now a centerline on the thick top edge and the same on the bottom thin edge was marked out. This is to aid the correct alignment of the segments during glue-up. I learned later (too late) that it would have been even better to mark the centers on all four edges, but it worked out fairly well anyway with only two marks. I didn’t get any photos of this, but it is pretty self-explanatory anyway.

With most of the 112 pieces cut, the next task was to start gluing up. The 1st photo shows a horn loose assembled before glue-up and the 2nd photo shows how the glue-up proceeded first in small sections to keep it all manageable. Both of these photos were of an earlier failed version with thinner walls, but they illustrate how it was done.

After gluing up the sections I wound up with the horn shown in the 1st photo above. The 2nd horn is still in sections awaiting final assembly and gluing. I plan to do that and also complete the final pieces in the center of the curls. The final job will be the sanding and then I can move on to the trumpet style tips seen in the pattern. These will be like bowls without a bottom and turned on my lathe.

I will continue this blog to the end so you can see the entire project carried out. Not sure how soon that will be as my health has been keeping me out of the shop lately, but not before after the holidays for sure.

Once again, thanks for following with and I hope you and your families have a very Merry Christmas and a Happy New Year!

-- Mike, an American living in Norway.

14 comments so far

View shipwright's profile


8816 posts in 4256 days

#1 posted 12-18-2019 05:17 PM

Best of the season to you Mike. You take care of yourself first, .... please.
Great project and blog.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View MrWolfe's profile


1846 posts in 1582 days

#2 posted 12-18-2019 06:58 PM

Great work Mike.
Yes, take good care of YOU.
Merry Christmas.

View mafe's profile


13872 posts in 4547 days

#3 posted 12-18-2019 07:41 PM

Amazing Mike, I raelly love the idea.
Thank you for bringing us.
All my best wishes for the health to be kind to you.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect.

View Redoak49's profile


5585 posts in 3447 days

#4 posted 12-18-2019 08:48 PM

Thanks for doing an interesting blog.

View doubleDD's profile


11288 posts in 3501 days

#5 posted 12-19-2019 02:43 AM

You’re doing great Mike. Like others have said take care of yourself first but I know what that can be like.
Maybe all this intricate work is driving you crazy too.
It sure is starting to look horny.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View stefang's profile


17040 posts in 4792 days

#6 posted 12-19-2019 10:46 AM

Thanks all for your input and encouragement. I’m really keen to finish this project after a long break. I hope it will work out ok and give a nice sound. I can’t wait to see them mounted and working.

-- Mike, an American living in Norway.

View justoneofme's profile


864 posts in 3938 days

#7 posted 12-19-2019 04:10 PM

Have a well deserved good winter’s rest Mike! All the best of this Christmas Season to you and Lilian!!

-- Elaine in Duncan

View stefang's profile


17040 posts in 4792 days

#8 posted 12-19-2019 06:36 PM

Same to you and your family Elaine. I’m afraid that ‘resting’ is doing me more harm than good. I’ve become all to fond of my easy chair this last year!

-- Mike, an American living in Norway.

View BlueRidgeDog's profile


918 posts in 1238 days

#9 posted 12-19-2019 08:20 PM

I just love projects you can hold in your hands, look at and think about without needing 40 square feet of space or manhandling 10’ boards through the planner or joiner. This one really looks fun.

View ocean's profile


232 posts in 2292 days

#10 posted 12-20-2019 02:40 AM

Amazing work. Love the work you have put into these. Can’t wait to see the final finished product. Happy Holidays.

-- Bob, FL Keys

View crowie's profile


5458 posts in 3409 days

#11 posted 12-21-2019 08:19 PM

amazing patience and craftsmanship Mike….

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View htl's profile


5624 posts in 2618 days

#12 posted 12-23-2019 12:02 AM

Very interesting and looking good!!!

-- An Index Of My Model making Blogs

View TopamaxSurvivor's profile


24606 posts in 5134 days

#13 posted 12-23-2019 06:31 AM

That is quite a project, Mike. Amazing! Merry Christmas!!

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5511 days

#14 posted 01-07-2020 06:39 AM

Very GOOD…


-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

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