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Need warbow arrows - cross post from arrow thread

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WillS:
Very slick looking! What made you pick that fletch shape? 

I'm always impressed by your horn inserts.  Mine never look that clean, despite having done hundreds!  Always find the slot is too big which means pinching the two halves together, or it's at a funky angle down the shaft.

adb:
I didn't pick the fletch shape... Matt did. These are what he wanted, so that's what I made him.  ;)

WillS:
Ah fair enough.  I'm sure you've probably mentioned this on one of your other arrow threads, but do you freehand the insert slots or use a jig? And what type of saw do you find works best? Numerous hacksaw blades taped together, or a tile saw?

adb:
I cut the horn insert slot into the end of the arrow shaft freehand on the bandsaw. I fit each horn insert piece individually, so the fit is not too tight or too sloppy. I leave the horn piece oversize, glue them in with 5min epoxy, and then trim and sand them to size, matching the shaft diameter. I cut the actual nock slot with a 1/8" diameter round tile cutting hacksaw. Works perfect. Then it's just sanding and rounding the end of the nock to make them pretty. Doing self nocked horn insert arrows shafts is very labour intensive. I think there's about 8 or 9 steps to get it right. Making the slots straight is just a matter of patience and practice.
Do you want a pictorial build along?

WillS:
Thanks for the info! No need for a full build along, it's pretty much exactly how I do mine, except I don't have a bandsaw.  I free-hand each insert slot using a couple of hacksaw blades or a tile saw, depending on the variant thickness of the piece of horn.  I'm very limited at the moment as I don't even have a workshop, so everything's held either in a dodgy old work bench or between my knees!

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