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One thing many wonder is, what does it look like at the shop of a working horn maker? Early this year I was able to visit the shop of Jim Patterson (Patterson Hornworks) in Las Cruces, NM (with the primary goal of getting a consult on an issue with my vintage descant), and while there took these views of interest.
To start off, new and recently completed horns were there to test. This photo shows one of their triple horns in nickel silver (an option that few makers can offer) and their Geyer and Knopf wrap horns (my current primary horn is their Geyer wrap horn). Not seen in these photos is another horn that was in the shop that day, recently finished, a wonderful descant I very much enjoyed trying briefly. I’ve said it before, this is a golden age for the horn; some of the very best horns and mouthpieces ever produced are currently on the market. The time to explore and look for your great horn is now!
I joked with the Pattersons that I would not give away any of their trade secrets, this being as close as I come. This unobtrusive looking pegboard with metal rods on it is actually one of the most essential parts of their business, as it contains the mandrels used to make their lead pipes and other critical parts. Tapered parts and tubes are rolled and seamed (the traditional way of makers of the past), then drawn over these mandrels. Those exact tapers and the method of making the parts are what makes a Patterson horn a Patterson horn, or what puts his touch on the horn of another maker, for example to upgrade an existing horn such as a Yamaha 671. Jim reports this current production instrument can be upgraded into a very fine instrument comparable to his own, an option horn players on a more limited budget should consider.
This third photo shows in the bottom half portions of two of the three (!) huge lathes in the shop. Having three, they are set up for different jobs, such as for valve rebuilding, etc. Lathes are used to turn metal parts to shape. I’ve done some work on horns myself, and would mention to readers that if you want to do more than simple repairs — if you want to seriously restore or build instruments — you need at least one of these machines and space (and skill!) to safely make use of it. Other tools seen in this view are also of much use in horn construction.
Finally we have another overall view of the shop and the workbenches from a different angle. Note all the bells hanging from the ceiling rack, and what about that brand new valve section at the bottom left? It is for a triple horn, and he is taking orders now for these or others of his models.
I have huge respect for the craftsmanship of all the horn makers out there, and very much enjoyed my visit with the Pattersons. If your travels ever have a chance to take you to Las Cruces, NM, you really should visit too. For more on Patterson Hornworks visit their website here: https://hornworks.com/
