Horn is an interesting material, I have tried using the abundant source (old Browning butt plates). The design is heat formed on these; trying to remove it is fruitless, as its ghost shows afterwards. I think you could make a curved plate by using a heat gun and form it to the butt, it saws on a bandsaw easier that it grinds. Repairs to a damaged or broken one is easily done with epoxy dyed black or dark brown, I have even replaced missing pieces with dark epoxy. It is also attacked by some type of insect as seen on some old guns. The dust when power sanding is bad and you should be careful about ingesting or breathing it as it probably is not good for your allergies.
