I just cut a horn fore end tip for a German sporting rifle I am restocking for a client this afternoon. Fast cut speeds and keep the bit moving so it does not smoke.
I have made several horn plates for clients, they are not fun but they can look really nice. Horn buttplates are very labor intesive and therefore costly as well, especially with a couple of fitted and engraved screws added in. I agree with Ted, horn plates are best kept thin.
I'm crazy busy lately and not taking any quick turn over work at the moment.
Try some guild members, several have experience with the process:
https://www.acgg.org/index.php/membership/find-a-member.html
