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I have wanted to take on this project for about 2 years now... and after some planning and thought (and help from youtube) I finally did it. As soon as my summer classes finished I began making the mold. I cut a huge piece of plywood (¾" thick), into 4 circles, and then spaced them vertically apart. I then put thin strips of scrap wood to give the shape of the bell. I used pipe insulation and bubble wrap to make the bend and the rest of the horn. The idea was, when the horn is done I can lift it up really quickly and the wooden mold I made will just fall out (and it did). Then I could reach up and pull out the pipe insulation.

Thankfully everything went as planned! I have a lot more work to do on the horn, its not nearly hard enough, and the inside isnt glued together very well. I was thinking about using some kind of wallpaper/long stips of paper as a final coat.. Does anyone know what kind of paper was used? I don't really want to spray paint this one, I think it would look better with a different finish.

I was thinking about posting about this project when it was finished.. but I was so excited when the mold separated I wanted to share! I wouldn't usually appear in my photos, but there was not other way to get an idea of the size of the horn without me holding it up. I look a little rough, as I got back from a camping trip today and didn't really sleep cause the moon was shining in my face all night (I like camping in my eno)

I didn't realize quite how big it would be until I started pasting paper on the mold.... its gonna be hard to put in the record room. I was thinking about making some sort of contraption that could hang the horn above my edison home..... Is it close enough to a cygnet? I'd love to hear any thoughts! I believe my horn is a little bigger than a real oversided EMG horn, but hopefully it works! I am slightly worried that the paper isn't hard enough and its absorbing all the sound... BUT one step at a time.


Cheers,

David

Congratulations! Impressive work.

No need to be concerned about your appearance. You look like one happy dude with your accomplishment in your hands.

David, nice job... How about some pics of the mold you made?

Also, acrylic Gesso will harden the paper mache and smooth out the finish...
Here is a website about making your own gesso: https://www.ultimatepapermache.com/home ... t-compound
I would read the directions and experiment with it first, before applying it to your horn.

Commercial artist gesso:
https://www.dickblick.com/products/utre ... gIDo_D_BwE

Curt A wrote:David, nice job... How about some pics of the mold you made?

That’s a secret


Jk! Here’s some pics of the mold. I worked with what I had..... so don’t judge

I just wondered what you might have used for a mold... it looks great and using what you had available is even better...

Now you need to make an EMG machine to go with your horn...

Curt A wrote:Now you need to make an EMG machine to go with your horn...

That’s next on my list

Wow David that looks amazing! It is only seeing you next to the horn that you get a good idea about the actual size of it.Its HUGE! I hope you can get it through the doors in your house? I can't wait to see it all finished off but it looks really good already. I bet it will sound amazing. Keep us updated.

Nice job. I have made horns for the Cylo-phone cabinets and one for a Multiphone. They sure are a labor of love. Lots of time. The Cylo-phone horn is in the cabinet for a fitting before finishing.

Phono-Phan wrote:Nice job. I have made horns for the Cylo-phone cabinets and one for a Multiphone. They sure are a labor of love. Lots of time. The Cylo-phone horn is in the cabinet for a fitting before finishing.

Boy those look amazing!! How’d you get them so smooth? You must reveal your secrets

David