Parts are CNC machined out of 3/4" Baltic birch Plywood and registered with dowel pins that should also prevent any splitting of the wood in time. The main profile is then rounded by hand. Oil finish.
Dimensions: 68 x 42 x 23 cm. Weight: 20 Kg.
![](https://1.bp.blogspot.com/-ldRSm3Low68/WMSrdgQ8F-I/AAAAAAAAB-g/s-uy3iCS5qko9m1fSIc-5g0DZP7QJCkbwCLcB/s640/sunship1315.jpg) |
104 pieces for a pair of horns.
Here, parts for the sides. |
![](https://2.bp.blogspot.com/-mbDUYVGgt6c/WMSrnNEnqCI/AAAAAAAAB-k/GDTHjz8vyKsdbipuBGh3LI_33Xla5aLyACLcB/s640/sunship1327.jpg) |
Parts for the main profile. |
![](https://3.bp.blogspot.com/-VqgyekW202s/WMSwtUYOuvI/AAAAAAAAB_g/Jqv7ZyjqrZIGgYQKShZimhsnRfu0x5ewQCLcB/s640/IMG_3660.JPG) |
Parts for the fins. |
![](https://2.bp.blogspot.com/-aN2WJx7Wmug/WMSsyADdjcI/AAAAAAAAB-0/4kIKGRRbOk4HusGRZIlFZZAA3dESl4k5ACLcB/s640/IMG_2067.JPG) |
Dowels register every piece
and prevent splitting.
There are 132 dowels per horn. |
![](https://4.bp.blogspot.com/-s44Zdv5LtpA/WMStXfGhFBI/AAAAAAAAB_E/7uoJ2MbKkUMIDyB3YcwQtdKz0oE5xF1_gCLcB/s640/IMG_2490.JPG) |
Main profile cut by hand. |
![](https://1.bp.blogspot.com/-UyW4I_8BEE8/WMSt4fHvGqI/AAAAAAAAB_M/McYlRh0GB0YEaU4HrtCRXVpxSfwO1oPYwCLcB/s640/IMG_4836.JPG) |
Assembly without any screws. |
![](https://2.bp.blogspot.com/-tNroeL9gJV8/WMSt_JMbSSI/AAAAAAAAB_Q/Vd8Blpt_j5EbLq8ZTn4p2B52_63rnG2vQCLcB/s640/IMG_4868.JPG) |
Still missing side boards. |
![](https://1.bp.blogspot.com/-e4Ypp_u7YSM/WMWoy9umJyI/AAAAAAAACAQ/ceW9G6gbJBYpz0nLBAu96ALg8_41SKxIgCLcB/s640/Sunship_4981.jpg) |
Rough sanding.
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You can make a horn by hand: