Stave shells are constructed in the same fashion as barrels.
Proficient drum craftsmen can agree on the viability of the stave drum shell, a classic favorite with a full, warm tonality. Wooden barrels are traditionally crafted in the same fashion, and the process of building a stave drum shell is simple, with a minimal range of tools and techniques required. Making mistakes when working with quality hardwood can be costly, but some simple steps will keep you on the path to success.
Instructions
1. Determine the dimensions of each stave that will compose the drum shell. Use a free online stave-shell calculator (see resources) to figure the dimensions and bevel needed. Make a note of them. The edges of the staves will need to be beveled so that when the staves are assembled they will form a cylindrical object, and not a flat surface. Use the stave calculator to calculate the amount of wood needed. Quality woods include, but are not limited to, maple, birch, oak, and beech.
2. Measure with a ruler the intervals determined by the stave drum shell calculator, and draw an outline of each stave on your plank with a sharp pencil. Check each measurement twice to ensure consistency of stave width. The slightest error at this stage will create a much vaster problem later in the construction.
3. Cut out the staves along the marked outlines with a saw. Ideally, use a band or table saw, but a hand saw will also work.
4. Stand the staves on end and arrange them to form the drum shell. Use a strap around the outer perimeter to hold them together. Don't glue them; this is a dry run. If the staves don't fit together, carefully sand as necessary.
5. Remove the exterior straps and separate the staves. Apply small amounts of wood glue to the inside portion of the contact edges of the staves, covering about 25 percent of the contact area. Reassemble the staves and strap them up again before allowing the glue to dry. The wood glue will dry and harden over a 48-hour period.
6. Remove any irregularities by lathing the exterior and interior surfaces of the shell. Manually sand the surfaces with sandpaper until both surfaces are smooth.
7. Carve bearing edges (the edges that will make contact with the drumheads) on the top and bottom of the shell. For a modern, open sound, cut 45-degree edges inside and out. Using a router bit that cuts rounded edges will provide a warmer, more vintage sound.
8. Apply masking tape over the bearing edges to protect them. Finish the drum shell by varnishing, painting, wrapping, or spraying polyurethane.
9. Calculate the distance needed between the holes for mounting the lugs by measuring the circumference of the shell and dividing that measurement by the number of lugs you want to use. Use a pencil to mark a small line where each lug will be placed. Put a drumhead and hoop on the shell, and screw a tension rod half way into a lug through one of the holes in the hoop. Place the lug against the shell and mark where each hole should be drilled. Use a length of string and a ruler to apply the same measurement around the shell.
10. Drill the lug-mounting holes, starting each hole with a smaller pilot hole if necessary.
11. Attach the lugs to the shell with screws and assemble the finished drum with heads, hoops, and tension rods.
Tags: drum shell, stave drum, stave drum shell, bearing edges, each hole, each stave