How To Make A Drum Shell
There are basically two ways to build a drum shell from your home or shop. You can build a stave drum shell or a segmented drum shell which is basically accomplished by gluing blocks of wood together, and then using a lathe and sander to smooth it out. This is usually a fall back method for many first time builders because it can be fairly easy.
But that is not to say a segmented drum or a stave drum is not worth your time and effort. Actually they are really cool looking, assuming you don't wrap it, and they can sound fantastic. The second way you can build a drum shell is to build a ply drum shell by gluing as few as 3 plys (or veneers) of wood together in a circular shape.
This can be challenging, but the results will be worth it. Today you are going to learn to build a ply drum shell. The first step to building a drum shell is to build a mold. You will need the mold because it will create the perfect circular shape. Without a mold you will have great difficulty making the correct bend and keeping the plys together. Each 12" board needs to have a 10" diameter hold cut so that we can fit the ply's into it.
Tip: In the United States the outside diameter of a shell is .125 inch smaller than the actual drum. How do you draw circle and cut it, There are many technical and simple ways to draw and cut a circle out of your wood or fiberboard. You can simply use a thumbtack, and a string.
Or you can use a wooden compass. I know builders who simply took either an existing drum or a drum hoop and simple used a pencil to outline it. It's up to you. To cut it you should use a jig saw. Lastly, you will cut all the boards in half. I'll explain why shortly.
Build A Drum Set In 10 Simple Steps! As I mentioned above you'll need to cut all the boards in half. The reason is because you are going to want to have access to the inside as you put the plys inside and fit them. You'll understand as you do this. Now that your boards are cut in half you will want to secure them all together, along with your 44 little separator pieces. You can use wood glue to accomplish this. After you do this you'll have to halves of your mold, and it's almost ready!
But you must be able to secure the two halves together as well. So what I used at first were two turnbuckles as shown below, and they work great. But what I am going to do instead is replace one of the turnbuckles with a large door hinge. This cuts my work time down and makes it easier to work with. After you install the turnbuckles and maybe a hinge, you are finished with your mold and you are ready to start putting your plys inside. Plywood, Plys, and Veneer get confused but they are basically the same thing.
A piece of plywood is made up of at least three pieces of veneer. So what you want to do is buy veneer. I would buy maple veneer because it is not very expensive and it's a good wood for drum building. There are different thicknesses of veneer. You should get at least 3mm. And you should consider doing at least 6 to 8 layers. Many drums are 8 ply, or in other words they have 8 layers of veneer. Some drum manufacturers use only three layers but each veneer layer is thicker than normal.
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