|Project by hairy||posted 10-13-2015 07:40 PM||1594 views||6 times favorited||9 comments|
Santa will have to stretch his toy bag to squeeze this in.
I used baltic birch plywood for this. 1/2” top and sides, 1/4” for the back and 1/8” for the front. The joinery is a dado/rabbit joint cut on the router table. The front and back are held on with brass screws.
This is an easy joint to cut, but should be strong enough. 1/4” bit, 1/4” depth of cut, 1/4” from the fence to cut both pieces. The inside of the box is reinforced with 1” x 1” hardwood strips glued in the corners. The bottom also has plywood blocks glued in place for the screws securing the feet.
I cut the soundhole, face side down, with a fly cutter. I set the drillpress to it’s lowest speed because the cutter is going 400% faster than the bit in the center.
Once the box was built I used a small block plane to make the joints flush. Then I put the back piece where it needed to be and held it in place with blue tape to install the screws. I flipped it over and did the same for the front.
Again with the block plane to flush cut the front and back to the sides, top and bottom.
The 4” soundhole is reinforced with a 3/4” thick x 2” wide hardwood strip across the back and just slightly above the hole. That’s how it will be picked up and carried, it needs to be strong.
After the finish dried, I put paste wax on the screws before installing. I read that some people tune the drum by loosening or tightening the screws. The top left and right corners of the face do not have screws, this is to give a slap sound when hitting the corner. I played around with using a snare, in the end I don’t like the sound so this one has no snare. I found the rubber feet on Amazon.
You sit on a cajon to play it. I sat on this and played it and I weigh a lot more than I wish I did. But, only time will tell how it holds up when Wild Thing starts thumping it.
I had a lot fun making this and learned a lot. If I do another, it will be different.
I made some points to hold up the front and back pieces while applying finish. All from scraps.
12” X 12” X 18” Minwax black stain and rattle can spray lacquer
-- stay thirsty my friends...