Making the horns

As the rebates are so deep I filled them in by gluing blocks. One for the rebate and one to get the overall depth the same as when the "bead pieces are fitted.

Then I cut the horn shape with my jig saw. This is far from ideal as the longest blades only just manage it. The blade wandered of perpendicular towards the bottom of the cut and it needed a sanding to get the shape right.

However, it worked out well enough.