Impala Horn Filler

[wmhammond]

Hello. I have an Impala Horn (antler) that I want to use as a knife handle. Problem is that it is hollow. In order to use it as a handle and have the kind of handle stability we all require I am going to have to fill it with some liquid that will pour into the hollow horn and then dry rock hard so I can then drill it out for the tang. Obviously, I can fill it with epoxy but I think it will be expensive and heavy. Any suggestions on a different filler that would be less expensive and and not so heavy but still structurally aound and that can be worked with woodworking tools. Thanks for the help.

Wallace

 

[Edwardshandmadeknives]

When I was a kid I made one with some impala horn for the handle. I used Bondo to fill it up. It worked, but it’s not something I would do nowadays. I think epoxy or Acraglass rifle bedding stuff would work better.

 

[FD Kingery]

What if you put in a wood dowel that was as big as you could fit in then epoxy that in place? Might keep the weight down and won't use as much epoxy. Keep in mind that the more mass epoxy has the hotter it gets and in the more brittle it becomes.

 

[wmhammond]

What would you guys think about a mixture of sawdust and wood glue?

 

[J. Doyle]

What if you put in a wood dowel that was as big as you could fit in then epoxy that in place? Might keep the weight down and won't use as much epoxy. Keep in mind that the more mass epoxy has the hotter it gets and in the more brittle it becomes.

I'd do this exactly.

 

[Edwardshandmadeknives]

What would you guys think about a mixture of sawdust and wood glue?

Wood glue would take forever to dry inside a handle and shrinks when it dries. The wood dowel and epoxy idea mentioned sounds pretty good though

 

[jmforge]

Epoxy doesn't weight much. Just make sure you use a filler or buy GOOD epoxy that already has filler added in like West G Flex.

 

[Oldnretired]

Bondo might work. It heats up quite a bit as it cures so I'm not sure how that would effect the horn. 24 hour epoxy heats up but not as much.
As far as wood goes, it would have to be a VERY stable wood and VERY dry I think and totally encapsulated in epoxy. Wood shrinks and expands with humidity and I could forsee problems down the road with srinkage/swelling with humidity or freezing temperatures.
I'm planning on doing the same with an impala horn and using K&G epoxy as I've used it before and like it alot. I plan on using a filler to keep weight down. I haven't decided on what filler yet but research on synthetics and epoxy compatibility should solve that problem for me. I just haven't done the research yet. Probably synthetic of some sort though for stability. Maybe I'll have to break down and but some of those micro ballons for epoxy I've read about.

 

[Gliden07]

I would get some of the Amazing Clear epoxy then you can color it in case you grind thru. This is the same stuff they use to make handles. I would get it at Michael's and look for a coupon too. Mix 50/50 put some heat to it to get rid of bubbles. Good to go! PS if you wanted to lighten it up they make a filler that is basically BB sized clear pellets that pour into cavity then pour epoxy over it.

 

[KenH]

What would you guys think about a mixture of sawdust and wood glue?

sawdust and epoxy perhaps. I don't know what wood glue would do, but epoxy should work fine.