23 September 2017
A pre-cut section of raw horn
A flat square-plate pre-cut piece of raw horn
Included supplies and tools
320 & 100 grit sandpaper
Fine-grade wire wool
Fine-grade metal workers junior hacksaw
Half round bastard cut 8" metal workers file
Araldite Instant Clear Adhesive
Take the tubular piece of horn. With 320 grit sandpaper sand the inside of the beaker, removing imperfections and rough bits. Sand along the grain of the horn. Using wire wool, work the inside of the tumbler, again along the grain, until quite smooth.
Take the flat square-plate piece of horn. Select which side you would like to become the inner base of your cup. Follow the process of step one sand a polish the chosen inner side. (It is helpful to wipe clean both the beaker and plate sections at this point.)
With Araldite Instant Clear Adhesive, adhere the flat square-plate piece of horn to the base (smaller opening) of the tubular piece. Apply a ring of glue around the bottom rim of the tumbler and with pressure stick it onto the chosen inner side of the plate. Wipe clean any excess glue on the inside with a damp cloth (white spirit is helpful here). Leave to set overnight.
Once fully set, trim the flat plate piece of horn down to size with a fine-grade metal hacksaw, cutting as close to the body of the beaker as possible.
File the plate closer to the correct dimensions using a metal file. Next, shape the plate down to its precise dimensions using 100 grit sandpaper. The base edge should now be flush with the walls of the tumbler.
Turning the cup upside down, place the rim on a flat surface. With the cup in one hand, level the base by moving 100 grit sandpaper back and forth. Turn the cup right side up and do the same along the rim. Lastly, smooth the rim's square lip until comfortable to the touch.
Finish your cup by polishing it to the desired look. With 100 grit sandpaper, work all the way around the surface of the horn. Repeat with 320 grit sandpaper. Lastly repeat the process with fine wire wool. Always working along the natural grain of the horn.
Using a clothe, wipe your cup over with a little olive oil. Lastly, coat the inside of the cup with melted beeswax. Be sure to allow the beeswax coating to fully dry prior to use.