[desertaliloff]

from my expeirence working with horn on Khukri's (another addiction) it does smell something awful but not as bad as the Laha (nepalese epoxy used to hold the handle on the blade) a trick I learned was to soak the horn in mineral oil for a few days then let it dry for another few days. This will help prevent it from shrinking with climate changes. CA glue also does wonders repairing cracks.

also I use a coping saw, files and sandpaper to shape it. I get the best finish taking it to 400 grit then buffing it with either a dremel or on a buffing wheel in my electric drill I put into my bench vice (poor mans buffer)