Inside Factory Amazing Process Of Making Buffalo Horn Beer Mugs | How To Make Things
In this video we show you how to make a Buffalo Horn Beer Mugs inside factory
crafting a beer mug from a buffalo horn entirely by hand! That's a rewarding endeavor, though it requires patience skill, and the right tools. Here's a breakdown of the process, keeping in mind that this is a general guide and specific techniques might vary based on the horn and your preferences:
Sourcing and Preparing the Buffalo Horn
Obtain a Suitable Horn: Look for a healthy, solid buffalo horn of the desired size and shape. Ensure it's ethically sourced.
Cleaning: Thoroughly clean the inside and outside of the horn with soap and water. You might need a long, thin brush to reach the interior
Disinfection: Consider disinfecting the horn with a mild solution of bleach and water (ensure thorough rinsing afterward) or rubbing alcohol. This is crucial for hygiene, especially if it will hold beverages.
Drying: Allow the horn to dry completely. This might take several days
Shaping the Horn
Marking the Cut Lines: Decide on the desired height and shape of your mug. Use a marker to draw clear cutting lines on the horn
Cutting: This is a critical step You'll likely need specialized tools:
Coping Saw or Hacksaw: For rough cutting. Work slowly and carefully.
Rotary Tool with Cutting Discs: Can be useful for more intricate cuts and shaping.
Initial Shaping: Once the main section is cut, begin to refine the outer shape using files, rasps, and sandpaper of varying grits (start coarse and move to finer grits). This will take time and effort to achieve a smooth, even surface.
Creating the Base (Optional but Recommended for Stability)
Material Selection: You can use wood, metal, or even a thicker section of another horn for the base.
Shaping the Base: Cut and shape the base to fit the bottom of your horn mug. Ensure it's flat and stable.
Attaching the Base:
Adhesive: Use a strong, waterproof, and food-safe adhesive suitable for the materials you've chosen. Ensure a secure bond.
Mechanical Fasteners (if using wood or metal): You could consider small screws or rivets, but be mindful of creating a watertight seal.
Hollowing the Horn:
Marking the Interior: Determine the desired thickness of the mug walls and mark the area to be removed from the inside.
Hollowing Tools: This is the most challenging part and requires careful work:
These are designed to remove material from the inside of the horn
Rotary Tool with Grinding/Carving Bits: Can be used cautiously to remove material. Work slowly and in stages to avoid cracking the horn.
Achieving Smoothness: Once the bulk of the material is removed, use files, rasps, and sandpaper (mounted on dowels or flexible shafts) to smooth the interior. This is important for both aesthetics and hygiene.
5. Creating the Handle (Optional):
Material Selection: You can use a piece of the same buffalo horn or a contrasting material like wood or leather.
Shaping the Handle: Carefully shape the handle to a comfortable grip. This might involve bending the horn with heat (requires caution and experience) or carving wood.
Attaching the Handle: Use strong adhesive and/or mechanical fasteners (if appropriate for the materials) to securely attach the handle to the mug. Ensure a strong and comfortable connection.
6. Finishing and Sealing:
Final Sanding: Use very fine-grit sandpaper to achieve a smooth finish on both the interior and exterior of the mug.
Polishing: Buff the horn with a polishing compound and a soft cloth to bring out its natural shine.
Sealing the Interior (Crucial for Drinkware): This step is vital to prevent leaks and ensure food safety. Options include:
Food-Grade Epoxy Resin: Apply a thin, even coat of food-grade epoxy resin to the interior, ensuring it seals all surfaces and any potential cracks. Follow the manufacturer's instructions carefully.
Beeswax: While more traditional, beeswax might require more frequent reapplication. Heat the horn gently and rub beeswax into the interior, then buff.
Sealing the Exterior (Optional): You can apply a clear sealant or varnish to the exterior to protect the horn and enhance its appearance.
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