This section is from the book "The Boy Mechanic Vol. 2 1000 Things for Boys to Do", by Popular Mechanics Co.. Also available from Amazon: The Boy Mechanic, Vol2: 1000 Things for Boys to Do.
Very artistic handles for hunting knives and carving sets can be made by using disks of horn. Procure some cowhorns from a slaughter house and split them with A saw, using only the large portion of the horn. The split horn is then heated by dry heat - an oven is best - then pressed between two cold plates to a flat piece. If well heated, it is surprising how easily this can be done. The piece is then cut into squares of suitable size which are marked and perforated in the center, the hole being a trifle smaller than the tang of the blade. The tang should be flat and a little longer than the desired handle, with the end made round and threaded for a nut.
Ill: The Finished Handle, If the Work is Well Done, is Easily Mistaken for Agate
A suitable washer is placed on the tang, which is then heated sufficiently to burn its way through the pieces of horn as they are put on the metal. When a sufficient number of disks are on the tang a washer should be slipped on and followed by a round nut. Pressure is applied by turning the nut and repeated heatings of the disks Will force them together to make perfect joints. Only a moderate pressure should be applied at a time.
The handle is now to be finished to the shape desired. If black and colored pieces of horn are interspersed, the finished handle will have the appearance of agate. The blade and handle can be lacquered and the ferrules nickelplated. - Contributed by James H. Beebee, Rochester, N. Y.