I'm making a 10-inch diameter x 7-inch depth suspended tom-tom for a
drum set using segmented turning techniques.
A few years ago, the place I was working was throwing away lots of
printing plate boxes. These came from Brazil, and had a two-inch-wide
board at each end of the box to keep the plates from breaking out. I
got about 200 of those boards over a three-month period.
I started my drum by cutting these boards into two-inch chunks with
15-degree miters at each end, then glued twelve of them into a circle.
(Right now you're going "where did he get these numbers?" Each ring has
12 pieces in it. Divide 360 by 12 to get 30, which is the number of
degrees in each corner. Now! If you are turning a corner by a
particular angle, half of that angle needs to be on each of the boards
that make up the corner. Half of 30 degrees is 15. As to the length, I
just picked a number that would be enough to make a ring at least 10
inches in diameter. The drum shell needs to be somewhat smaller than 10
inches so a standard head will fit on it. This one's 9.25 inches in
diameter, so I'm fine.)
Okay. Onward and upward. My original plan was to cut out 84 little
pieces of wood, glue them into seven rings, then glue the rings into a
stack. I glued up the first ring and left it to dry overnight.
Surprise: the pallet-grade wood that comes from Brazilian forests is
more open-grained than red oak. It wicked all the glue up into the
pores and the ring I made fell apart. On to Plan B.
Last Wednesday was my day off. On the way out of the store on Tuesday,
I stopped by tool rental and bought a big sheet of the self-adhesive
sandpaper we sell for floor sanding. We had 36 grit and 60 grit in
stock. 36 grit sandpaper has boulders glued to it; I got a sheet of 60
grit. I stuck the paper to a sheet of plywood. I sanded one face of
each of 24 blocks smooth, then glued them up into a two-layer ring
that's offset 15 degrees, put the ring between two sheets of melamine,
and put them in my hydraulic press. I then had dinner while the glue
dried under a bit of pressure--maybe 100 pounds, certainly no more.
Two hours after applying pressure, I sanded the sides of the ring on
the large sandpaper and added two more layers, one on each side. Once
again, two hours of pressure and sanding. Eventually, I had seven
layers built up. I set my kitchen oven to "Warm," put the drum shell
blank on an old cookie sheet, and baked it for two hours to get it good
and hard. Then I put the blank on my workbench and left it overnight.
The next day, I cut out a piece of plywood, glued some construction
paper to it, glued the blank to that, and put it on my lathe. I used
gouges and skews to make the outside round and the size I wanted, and
gouges, skews and some scraper work to make the inside round and the
walls half an inch thick. Then I sanded it and oiled it.
The way you tell whether a drum shell is any good is to take all the
hardware and the heads off it (or don't put any on yet), suspend it off
your little finger and rap on it with your fist. This one sounds really
good. It's got a nice crisp sound with no trace of muddiness to it.
This is going to be a great sounding drum. It's going to be a great
looking drum too--as you turn the drum around in your hand, the
individual blocks change color from a dark red to almost white. Think
"Chromalusion" but this doesn't rely on high-tech finishing to achieve
the effect; this is just how it is.
Right now I'm busy applying coats of oil to it. I'm going to put a
total of 14 coats of oil on the shell, one per day. After it's been
thoroughly oiled, I'll let it sit for a month to get good and dry, then
apply probably ten coats of Minwax finishing wax with an electric
lambswool buffer. Finally, I'll put in the six vent holes, add an
internal microphone mount and an XLR connector, make some hoops so I
can head it, add lugs and heads, and start on the next one--I need a
total of seven.
Where this is going to get fun is when I do the bass, the snare and
three of the toms: None of those drums will fit on my lathe, so I'll
have to use a Surform tool to shape them. All of those drums will be
made from cherry, walnut and hickory--I don't have nearly enough of the
Brazilian wood to make a bass drum, and cutting a million little blocks
of wood on a compound miter saw is NOT my idea of a good time!
--
--jmowreader