Last volume was dealing with the final shaping of the horn- lam. Now the horn- lam has to be backed with sinew- fibres. But before backing the prod has to be wrapped with bundles of sinew- fibres.
About a quarter of prod´s thickness will be the sinew- backing, 3- 4 layers of sinew- fibre- bundles has to be prepared. According to a total length of 30″ minus the recurves about 25″ of the prod´s length and an average- width of 2″ incl. the sides of the prod , so about 50 sq.inches have to be backed. As a total that means 4-5 buffalo- leg- sinews have to be spliced, at least a job of 8h.
Waiting time! At first I planned to finish the prod in April or May, that´s to less time for the polymerisation. I´ll do it at the end of August, 9 month after having backed the prod.
So next volume will be focused on the braced and ready to final tiller- work prod.
The first bracing of the crossbow will be soon, I think it will be in April, my report about its making of is time delayed.
After having “puzzled” pieces of horn to a solid block, the block needs to be roughly shaped and the recurves have to be attached. I wanted to use antler as recurves, but I can´t get any antler solid enough for a heavy hornbow, so I ended up in using tips of the waterbuffalo- horns I´ve used anyway for the bow.
There is a slight reflex in it, that´s what I wanted, don´t care about any imperfections here, the hornbow needs to be shaped, it´s still to wide, to thick to long.
The bow has to be cut according to a centerline at 23″ in length, width is 11/2″ in the center, tapering to 1″ at the beginning of the recurves, thickness is about 3/4″ . Thickness and oval cross- section will be worked before wrapping and backing bow.
The recurves will be spliced in, the splice measures 3 3/4″ in length, the recurve itself is 4″ in length. So the bow will end up at 31″ in length.
A v- splice is stable enough, even at such high draw- weights, the bow will be wrapped with sinew- fibers completely and sinew- backed. When the splice is cut the recurve will be worked for to fit in the bow.
For a proper glueing all glue lines are criss- cross hatched with a saw- blade, before final glueing is done, the glue- lines have to be coated with a thin solution of hide-glue.
Next volume is dealing with the shaping of the cross- section, the wrapping and backing of the bow with sinew.
That´s a typical medieval crossbow. Its bow is made of horn, backed with 2- 3 layers of sinew, wrapped with sinew and covered with birchbark. The bent ends or recurves of the bow are made of another spliced in piece of horn or antler. These crossbows are told to draw 150- 300lbs. The bow measures in length 30″ – 35″, at the handle width is 2″, at the ends( just where the recurves are beginning) width is 11/2″, thickness is about 3/4″ at the center tapering down to 1/2″ at the ends. The recurves are measuring about 31/2″ in length.
The horn slats are assembled like the stones of a dry stone wall, no running through seams or joints. It would be no problem to use thinner horn slats, it depends on the available material, so their could be 7 rows of horn slats adjoined. The lengthwise joints are butt joints at a 45 angle.
First is to glue the orange slats, then insert the black slats, last add the red and green slats to the sides. So there are 5 rows of slats. The back of the assembly of horn slats will be cut even, rasped to an even thickness and width, than the tapering in width and thickness has to be done. The rectangular cross- sections will be rounded more towards the belly of the bow. Time for a first test of tiller(even bending), drawforce, any sounds of breakage??.
In the drawings of the cross-sections the sinew- backing is marked blue.
The cross- section at the left is another way to do a hornbow for a crossbow. Just glue at least 2 slats together lengthwise one upon the other and sinew- back them. This is an easier way. But it is not recommended for really high drawweights up to 200- 300lbs……………..and it´s hard to find horns measuring such long enough with a roughly even required thickness. The dry stone wall method makes a more effective use of the entire horn.
Next volume is focused on the next step of the making of the “dry stone wall”, and I hope so, on sinew- backing in general.
Here we´re: 2 pairs of waterbuffalo- horns cut into strips( outer and inner curve, sidewalls), a bundle of 12 leg- sinews of elks, a mountain- maple bowstave and a bag of hide- glue.
Here we go: I´ll post the step- by- step making of a hornbow(hybrid- style) and of a hornbow for a crossbow(medieval European style, about 150lbs).
You know, I´m very ambivalent about hornbows, I admire the making of a hornbow with all its cultural backgrounds, I´ve been involved into the reconstruction of Scythian, Greek and Parthian hornbows for years. For to tell the truth, hornbows have never blewn me away. The term hornbow is totally overloaded with myths, mares and nightmares, arrogance, mistaken masculinity………………….a hornbow is a very ineffective way to make a bow. Anyway it´s fascinating, maybe that´s the magic of horn.
Horn has been reduced to be a main symbol of male power, but remember the unicorn, the cornucopia. It is still used by some tribes and people for to receive cosmic vibrations in rituals or for to enforce the power of organic fertilizers or it is a fertilizer itself. Horn is still a material for to make jewelry, cups, drinking horns and combs. Book covers had been made of horn.
Horn is an ingredient of remedies, mainly for to enforce male virility, but it is also known as a kind of emergency remedy.
In craftmanship horn is used as a stabilizer, when compression strength is needed. Due to its density it serves well as a container for liquids. Chemically horn is a polymer and is made of keratin, a protein that is building long molecular chains. Keratin is the basic component hairs, claws, finger nails and scales are made of.
When engineers tried to develop the first plastic materials horn was the model: they wanted to create a dense, resilient, break- prooved, and temperature- resistent material. Charles Goodyear succeded in inventing ebonit, the first volcanic rubber. Next one was the invention of galalithe, which really looks like horn, radio- cabinets and small boxes for cigars and cigarettes were made of it.
Horn is by far the most compression- strong natural material. Its modulus of elasticity value is great, you can compress a piece of horn at 10% of its length, it´ll always reconstitute its original length. So it is an ideal material for to make bows.
Its main disadvantage in making bows of it, is its high physical weight, so its use in a bow should be reduced to the compression- range of the limbs of a bow. So it is a matter of course to make a hornbow as a relatively short bow too. The shorter a bow, the more tension is stressing the back of a bow, a hornbow without a sinew- backing for to reduce tension strength will not work. A core of wood works as a kind of adjustor between the sinew- backing and the horn. The wooden core is needed for to keep the bow in line, for to withstand humidity, the ancient hornbowyers have called the wooden core the skeleton of a hornbow.
First step is to get the horn. Nowadays we´ve to buy it, our ancestors were carefully selecting the horns needed for to match the required quality. They even observed the buffalo or ibex: were they nourished well, to old, to young………….they had to take the best horns what they had been able to find. Actually the best horn to get is horn of water- buffalos, it is big, long and straight. The water buffalo is not an endangered species. The horn- supplier of my choice is Highlandhorn, run by Martin Hyslop in Scotland. Martin knows what hornbowyers are longing for, you can even tell him what kind of hornbow you want to make, he´ll serve you well. Maybe there´ll be problems with the customs, ask for it. Martin knows that a hornbowyer needs identical horns, a so- called pair of horns. The radiuses of the horns have to match, that´s for to get symmetrically bending bow- limbs.
Usually you get from Highlandhorn what I´ve posted above. Next step is to cut the bottom of the horn even and to plane its outer and inner curves. For to make a hornbow for a crossbow the sidewalls have to be planed too. The hornbowyers are looking for the outer curve of the horn, cause you can cut a long and wide strip of it.
Horn is a natural material, it grows like wood, there´re growthrings, if they are cutted the horn will break. So the sidewalls can´t be used for a hornbow. The hornbow of a crossbow is made like a dry- stone wall, that´s a different principle of construction.
In former times hand tools had to be used for to work the horn. That´s not that hard you may think of it. I´ve done my first horn bows with axes, saws, rasps…….knives, above all for to get a feeling of the material itself. Sometimes I´m still working horn with hand tools, it is an outstanding experience, but usually I prefer a flex for to cut and plane horn. Some hornbowyers advice the use of a bandsaw for to cut a horn, hands off, that´s really dangerous! I´m a former cabinet maker I really know to get by with a bandsaw and I´ve cut horn with it, but severeral times there had been some risky situations, for not to talk of the disrupted saw blades.
Sometimes the grooves in the sidewalls are to deep for to be planed, leave them and try to get by with the remaining wall.
The bottom of the horn is very thin, for a hornbow a thickness of at least 1/8″ is required, so some horn should be cutted off. The tips of a horn are solid and thick enough, they will be the belly of the bows handle.
The required width is about 1″ – 13/4″, twists can be adjusted with heat. Don´t use horn to much twisted anyway, horn is always trying to reconstitute its original grown shape.
So what a hornbowyer is usually longing for should be a long, wide, almost rectangular, not twisted horn with no deep grooves. That´s a dream, sometimes you´ll meet horns like that. Usually there´ll be some problems.
Next volume is focused on preparing the horn for be glued to the wood and the making of the hornbow for the crossbow: thickness, width, grooving.
Sorry, I´ve announced the Hornbow Vol.1 to be published today, but when beginning the article I can´t find the corresponding pics. I was almost flipping out, but finally I met the pics in a false folder.
O. k., that´s history, tomorrow, maybe Sunday Hornbow Vol.1 will be out.