I chose to make Ram's horns because they are Large scale.
What you will need :
(2) Wire hangers - Free
(1) Wire cutters/pliers - Free
(1) long wooden dial - Walmart .50cents
(1) Jewelry wire - Walmart $1.30
(1) low temp glue gun - Walmart $5.00
(1) exacto knife (Box cutter) - Free
(2) packages of low temp glue - Walmart $3.50
(1) pipe insulation foam - Hopme Depot $2.00
Scrap material ( I used a old pair of hospital scrub pants) - Free
(1) roll of wax paper - Free
(5) packages of foam cord - Home Depot $3.48 each
(1) roll of crepe paper or streamer paper - Free
(1) paper mache' kit ( I used flour and water) - Free
(1) tube of Acrylic paint - Walmart $3.00
(1) package of cheap sponge brushes - $1.00
(1) headband - Free
(1) ducktape - Free
If you see Free beside the item, it just means I had the product at home and just used what I had. :)
Step 1: Making the mold
From there I took a 40 cent wooden dial that i purchased from Walmart and made (8) 2 inch mini dials. This would make sure my mold stayed sturdy. Once the 2' dials are hot glued in place, I took an extremely thin wire (typically used for making jewelry) and zig zagged it from the bottom base to the tip of the wires and closed both wires with a rubber band.
Step 2: Adding insulation
The hot glue will begin to slightly burn the insulation on the inside, this will allow for it to fit snugly around the edges of the mold. This is a good thing! After all the insulation has been laid on each side of the mold, double check to make sure you have covered the very tip of the the horn, you don't want any wire exposure.
Step 3: Covering with cloth
If using hot glue YOUR FINGERS WILL GET BURNED! This step was very painful because you want to pull the fabric taught over the form and the only way to achieve that is to hold down the areas where you have applied glue. I was using Hot glue, but for you... I suggest using an aresol spray glue such as Super 77 which can be found at Walmart for $4.88 in the craft section.
Step 5: Wax paper essentials
Now that your horn form is smooth and covered with a thin cotton cloth, take wax baking paper and cut it into 3' wide strips. I would start at the pointy end of your form because as I learned, by now your form has a rounded tip. This way you can cover the tip of the form and still continue with a smooth layer as you hot glue the wax paper the rest of the way down. Again when using hot glue be careful of your fingers.
Step 6: Foam Rope
Step 7: Wrapped in Foam
Once the foam cord (Backer Rod) is taken out of its package you will see that it is a very long cord of foam. Take the Backer Rod and cut it maybe about 4ft long and take a dot of hot glue and start at the Base of the horn mold and press the Backer Rod to it. The wax paper does not adhere to hot glue very well, so you do not have to worry about the Backer Rod sticking to the wax paper very much. Begin wrapping the cord around the form. As you go up lay strips of glue on the Backer rod, it will melt the foam slightly, again this is a good thing because it will create a seal in between each ridge. Continue wrapping until you get the end of the horn.
Step 8: Crepe paper
Now that you have a foam horn, you will notice that its lost a little of its twisted ram shape, this is easily solved by taking two more wire hangers, straightening them out and then bending them into the same shape as your original base horn mold. A little hot glue at the bottom and the tip will secure it inside. Once you have your shape the way you originally wanted it, begin placing the crepe paper around the horn.
I chose to forgo the hot glue for this, it was just unnecessary, simple scotch tape will do. Just be sure to pull the crepe paper as taught as you can with out tearing it.
Step 9: Completed crepe horn
From this point you would return to your original Horn mold that is still wrapped in wax paper and begin the process of wrapping it in foam Backer rod, then removing it from the form and wrapping it in crepe paper to make a second horn.
Step 11: Triming
Step 12: Headband
With a sharpy I marked where the head band would would need to sit on my head in order for the horns to be level with one another. I then took my Exacto knife and cut away all the foam until it was a shape of a C, This would allow the head band to fit with out any problem. I applied glue to the horn foam Not the head band. This way i would place the horns exactly where I needed. I did this with out help, so it was a shot in the dark trying to make sure both sides would be level over my shoulders.