Tongue drum teacher

Tongue DrumInstruction Booklet

Glossary of Tools and Equipment

Bouncy Ball Bench Hook Paint Brush Damp Cloth

Cork Block Disc Sander Dowel Garnet Paper

Jack Plane Nail Punch Panel Pin Pedestal Drill

Pencil Timber Putty PVA Glue Rule

Safety Glasses Scroll Saw Tenon Saw Try Square

Vice Warrington Hammer Timber Oil

Step 1: Measuring and Marking

Action Tools/Equipment Processes/Techniques Safety You will be given a LENGTH of

TIMBER. You will need to make four

parts for this drum (two sides and two ends)

Timber 850mm(l) x 70mm (w) x 12mm (t)

Measure and MARK OUT sides and ends.

Your sides should be 300mm and your ends should be 110mm.

Pencil Rule Try Square

Leave a 5mm gap between each part for waste.

Measure from face side and face edge.

General Workshop Safety

Measure your sides and ends one more time to make sure they are the correct length.

Colour in the gaps between each side so you can see where you need to cut.

Pencil Rule

Measure from face side and face edge Use a zig-zag pattern to colour in the

gaps


Step 2: Shaping

Action Tools/Machines/Equipment

Processes/Techniques Safety

Cut sides and ends. Remember to cut in the gap area.

Bench Hook Tenon Saw Vice

Place the bench hook in the vice. Clamp it.

Lay your timber on the bench hook. Hold your timber and start cutting with

slow small strokes on far edge.

Wear eye protection Keep fingers away

from saw blade

Trim sides to length by sanding to the lines you have marked.

Disc Sander Hold work flat on table with both hands.

Use the side of the disc moving downwards.

One only to use machine.

Wear eye protection Use dust extractor

Trim ends to length by sanding to the lines you have marked.

Disc Sander Hold work flat on table with both hands.

Use the side of the disc moving downwards.



Step 3: Surface Preparation

Action Tools/Equipment Processes/Techniques Safety Sand inside surfaces with coarse

Garnet Paper to remove any pencil marks and dirts.

Cork Block Garnet Paper

Sand along the grain. Use a coarse grade (60) to remove all

pencil marks and other stains.

Beware of sharp edges.

Wear a dust mask if needed.

Sand inside surfaces with fine Garnet Paper to make smooth.

Cork Block Garnet Paper

Sand along the grain. Use a fine grade (180) to make

smooth.

Beware of sharp edges.

Wear a dust mask if needed.

Q1 Why do we sand along the grain instead of across the grain?

Sanding along the grain helps to hide the “scratch” marks.

Sanding across the grain makes the “scratch” marks easy to see.

Q2 Why do we call the action “sanding”?

The original type of abraisive material was sand.Ancient people glued sand onto animal hides.

Step 4: JoiningAction Tools/Equipment Processes/Techniques Safety

Test fit with a trial assembly without glue.

Quick-Release Clamp or Vice

Put the sides and edges together to test whether your parts fit together correctly in the vice or clamp.

If they do not fit go back to shaping stages (step 2)


Apply PVA glue to the “end grain” of the End pieces.

PVA glue Damp cloth

Lay end pieces, face up, on the table. Put a light layer of PVA glue along the

“end grain”


Assemble sides and ends to make the carcass (box frame).

Sit each ‘end’ on each layer of glue. Make sure the edges are flush.


Allow glue to bond Carefully hold the ‘Ends’ down for 30 seconds so that the glue bonds.


Clamp the carcass in the vice or quick-release clamp.

Quick-Release Clamp or Vice

Damp cloth

Make sure the edges are flush. Ask teacher to check. Wipe off excess glue with damp cloth Your project can dry on the table.


Q1 What does the acronym PVA mean?

Poly-Vinyl-Acetate

Q2 Why do we test with a “trial assembly” instead of just gluing straight away?

To make sure that you have all the right equipment and that you can clamp the carcass together before the glue dries.

Step 5: Making the base

Action Tools/Equipment Processes/Techniques SafetyMeasure and Mark

You will be given a LENGTH of plywood to make the base of your tongue drum.

Plywood 310mm (L)x 140mm (w) x 5mm (t)

Beware of sharp edges and splinters.

Measure and MARK OUT the base.

The length should be 310mm and the width should be 145mm.

Pencil Ruler Trysquare

Measure from face side and face edge. The base should be slightly longer than

the carcass.


Cutting and Shaping

Cut out the base to length. Bench hook Tenon Saw Vice

Place the bench hook in the vice. Clamp it.

Lay your timber on the bench hook. Hold your timber and start cutting with



from saw blade

Write two sentences that describes one of the above actions, that includes tools/equipment, processes/techniques and safety.………………………………………………………………………………………………………………………………………

Example (see the highlighted action in the table above):

Measure and mark out a length of plywood for your base to 310mm long using a pencil, rule and trysquare. The base should

be slightly longer than the carcass and beware of sharp edges and splinters.

Step 6: Joining

Action Tools/ Equipment Processes/Techniques Safety Get your carcass and place it on

the table with the open side facing you.


Apply PVA glue to edges PVA glue Put a thin layer of PVA glue along all edges of the box.


Glue the base to the carcass Carefully place your base on the glued edges.

Make sure the edges are overhanging all sides and ends.


Allow the glue to bond Carefully hold the base in place for 30 seconds so that the glue can bond.


Nail the base to the carcass. Warrington Hammer

8x 15mm panel pins

Start nails with pointed end of hammer. Wipe off excess glue with a damp cloth


Wipe off excess glue PVA glue Damp cloth

Wipe off excess glue with a damp cloth General Workshop Safety

TERM BANK: panel pins; PVA glue; Warrington Hammer; carcass

Q1 Your base piece of plywood is represented by the shaded section above. How many base pieces can we get out of a sheet of plywood (represented by the table above)…………………………………………………………………Q2 If a sheet of plywood costs $150, how much does your piece cost?..................................................................................................

Step 7: Shaping (trimming the base to size)

Action Tools/ Equipment Processes/Techniques Safety If the base overhangs the sides

you will need to trim the base to fit the carcass by using a plane.

Vice Jack plane

Clamp the carcass into the vice Plane the overhanging edges with

smooth strokes.

Wear eye protection Keep fingers clear of

plane blade.

If the base overhangs the ends you will need to trim the base to fit the carcass by using a disc sander.

Disc sander Hold work flat on table with both hands.

Use the side of the disc moving downwards



TERM BANK: Jack Plane; work flat; overhanging edges; disc sander; plane; overhangs

Write number sentences to answer these questions

Q1 Your base piece of plywood is represented by the shaded section above. How many base pieces can we get out of a sheet of plywood (represented by the table above)………………10 columns multiplied by 5 rows equals 50 bases…………………………………………………Q2 If a sheet of plywood costs $150, how much does your piece cost? 150 dollars divided by 50 bases equals 3 dollars

Step 8: Surface Preparation (of the joined carcass and base)

Action Tools/ Equipment Processes/Techniques Safety Punch panel pin heads below the

surface. Warrington Hammer Nail Punch

Align the tip of the nail punch to the head of the panel pin

Carefully hammer the end of the punch

General Workshop SafetyBeware of sharp edges

Fill nail holes and other small gaps with putty.

Wood putty Place a small amount of putty on the tip of your finger

Press it into any holes or gaps Smooth it over


Sand outside surfaces Cork block Garnet Paper

Sand along the grain Remove all machine scratches with

coarse paper (60) Use a fine grade (180) to make

smooth.


TERM BANK: Cork block ; Nail Punch; hammer; machine scratches; Wood putty; holes or gaps

Q1 Why do we punch the panel pin heads below the surface?

The nails are different in colour to the pine timber and this would not look as nice.

Using a pine coloured wood putty hides the look of nails.

Q2 How could you make your own wood putty?

Use fine pine wood dust and mix with PVA glue.

Q3 How did the ancient Egyptians make their wood putty? http://www.reshafim.org.il/ad/egypt/animal_products/From animal bones. “Gesso, a mixture of glue and plaster of Paris was used as a sort of glue putty for smoothing wooden surfaces before painting or repairing flaws in stone sculptures.”

Step 9: Making the top

Action Tools/Equipment Processes/Techniques SafetyMeasure and Mark

You will be given a length of Fijian Mahogany to make the top of your tongue drum.

Fijian Mahogany 310mm (L)x 140mm (w) x 16mm (t)


Measure and mark out the base. The length should be 310mm and

the width should be 140mm.

Pencil Rule Trysquare

Measure from face side and face edge. The top should be slightly longer than

the carcass.


Cutting and Shaping

Cut out the top to length. Bench hook Tenon Saw Vice

Place the bench hook in the vice. Lay your timber on the bench hook. Hold your timber and start cutting with



from saw blade

TERM BANK: Tenon Saw ; 310mm; Mahogany; width; top; timber; Cutting and Shaping; bench hook; Rule; saw blade; splinters; Measure and Mark; longer; slow small

Q1 Describe Fijian Mahogany in terms of colour, grain, uses hardness and location.This is the Brazilian Mahogany plantation timber grown in Fiji. Timber is an orange brown colour, medium hardness and is good for furniture and musical instruments.

Q2 Why use plantation timber.Native trees are important for the world ecology. They provide homes for thousands of other plants, insects and animals. They are also important for the atmosphere, converting CO2 gas into oxygen.

Step 10: Making the Top Action Tools/ Equipment Processes/Techniques Safety

You will be given a piece of paper.

Draw the design you wish to have on the tongue drum

Paper Pencil Rule

Copy the design you have drawn onto your top.

Pencil Rule Try Square

Bore holes in the top Drill Press Hold work flat on table. Apply even pressure or clamp.

Wind the handle down slowly.


Wear eye protection. Restrain loose clothing

and hair.

Cut design into lid. Scroll Saw Hold work flat on table. Apply even pressure.


Wear eye protection. Keep fingers clear of

blade.

TERM BANK: Drill Press; Pencil; clamp; blade; Scroll Saw; Restrain; design; Bore; pressure; Try SquareProportion refers to the way a design is divided into its portions, segments or parts. For example: A large proportion of the wall design was rendered in concrete and a smaller proportion was taken up by bricks. A table might be considered well-proportioned if its legs seem to carry the weight of the table top easily.However, it might be considered 'out of proportion' if a heavy, thick table top is supported by very thin tapering legs. A coffee pot could have a very large handle in proportion to the body, or the opposite proportions. Creating designs with eye-pleasing proportions can be assisted by an ancient mathematical method. This method was often used to work out proportions for buildings, room plans, furniture and even paintings.

Four names for this mathematical principle are hidden in these letter sequences. To solve them, make two words out of the letters, reading from left to right. The letters are in their proper order, as you can see in the example. Hint: In each term, the first word is GOLDEN. a. G R O U L D L E E N: Golden Rule

b. P R O G P O L O R T D I E O N N: Golden Proportion c. G O M L E D A E N N: Golden Meand. G R O A L T I D E O N: Golden Ratio e. S E G O C L T D I E N O N: Golden Section

Step 11: Joining (the Top)Action Tools/Equipment Processes/Techniques Safety Get your drum base and place it

on the table in front of you.

Glue the top to the carcass PVA glue Damp Cloth Vice and/or

Place a thin layer of PVA glue along all the top edges of the drum base.

Carefully place your top on the glue. Make sure the top overhangs the edges. Carefully hold the top in place for 30

seconds so that the glue can bond.


Clamp tongue drum to dry Vice and/or Quick-release clamp

Place your tongue drum in a vice and clamp until dry.


Wipe off excess glue Cloth Wipe off any excess glue with a damp cloth.


Use the table below to evaluate your progress so far.

Cutting and Shaping Very little straight cutting Little evidence of appropriate use of tools Shaping does not match marked lines

Mostly straight cutting Evidence of good use of tools Mostly shaped to marked lines

Perfectly straight cutting Evidence of excellent use of tools Accurately shaped to marked lines

____ x 1 = ____ ____ x 3 = ____ ____ x 6 = ____Joining and Assembly

Some joins are square and flush Some accurate assembly (nailing, gluing and other

fastening)

Most joins are square and flush Mostly accurate assembly (nailing, gluing and other

fastening)

All joins are square and flush Accurate assembly (nailing, gluing and other

fastening)____ x 1 = ____ ____ x 5 = ____ ____ x 10 = ____

Step 12: Shaping the TopAction Tools/Equipment Processes/Techniques Safety If the top overhangs the sides you

will need to trim the top to fit the carcass by using a plane.

Vice Jack plane

Clamp the carcass into the vice Plane the overhanging edges with

smooth strokes. Plane with the grain

Keep fingers clear of plane blade.

If the top overhangs the ends you will need to trim the top to fit the carcass by using a disc sander.

Disc sander Hold work flat on table with both hands.

Use the side of the disc moving downwards



Round the top corners. Jack Plane Clamp the carcass into the vice Plane a 5mm chamfer on each side at

the top with smooth strokes. Plane the corners created by the chamfer Continue removing the corners until

rounded.

Keep fingers clear of plane blade.

TERM BANK: chamfer; work flat; blade; disc sander; Jack plane; trim; overhanging edges.

Q1. Read the process of rounding the corners and “sketch to stretch” in the boxes below to help describe the way in which the rounding will look.

Step 13: Final Surface PreparationAction Tools/Equipment Processes/Techniques Safety Fill small gaps with putty. Wood putty Place a small amount of putty on the tip

of your finger Press it into any holes or gaps Smooth it over

Fill nail holes and other small gaps with putty.

Sand outside surfaces Cork block Garnet Paper

Sand along the grain Remove all machine scratches with

coarse paper (60) Use a fine grade (180) to make smooth.

Sand outside surfaces

TERM BANK: holes or gaps; surfaces; machine scratches; Wood putty; Cork block

Calculate the cost of the radiate pine (used for the carcass construction) and Fijian mahogany (used for the top)Use the following information70mm x 12mm radiate pine (D.A.R ) costs $5.50 per lineal metre140mm x 20mm Fijian mahogany (D.A.R ) costs $15.00 per lineal metre

Q1. Given that you used approximately 1 metre of 70mm x 12mm radiate pine (D.A.R ) was used to make the carcass, what is the cost of timber? ……………………………………

Q2. Given that you used approximately 0.333 of a metre of 140mm x 20mm Fijian mahogany (D.A.R ) was used to make the carcass, what is the cost of timber? ……………………………………

Q3. What does the acronym D.A.R mean? ………………………………………………………………………………………

Q4. Describe a lineal metre? ………………………………………………………………………………………………………

Step 14: FinishingAction Tools/Equipment Processes/Techniques Safety Apply lacquer to your tongue

drum. Paint Brush Lacquer

Dip the bottom third of the paint brush into lacquer jar.

Lightly wipe the excess onto the side of the jar’s mouth.

Brush along the grain. Check the corners for drips and ‘touch

up’ as needed.

Wear dust mask

Oil your tongue drum Rag Wood Oil

Put oil on a rag and rub over tongue drum.

Sand in with wet/dry sandpaper along the grain.

Wipe down with a clean rag

TERM BANK: drips; dust mask; lacquer; Wood Oil; along the grain; jar’s mouth

Use FOR strategy of Monitoring For this next section of text students will be using the coding strategy to develop their understanding. Write the following codes on the board: = I understand ? = I don’t understand. ___________ (under a word)= I don’t know this word

Wood finishing is the application of paint, lacquer or other finishes to the surfaces of timber for the purposes of: 1. Preserving the wood. 2. Improving the appearance of the project.

Before wood finishes are applied, the surfaces must be prepared properly (see Step 13): -Be perfectly smooth by filling all holes with wood filler and then sanding.-Be dry and free of oils, dust and dirt. -Have sharp comers (arris) lightly sanded.

Wood finishes may be applied by brush, roller and rubbing cloth or by spraying from a can or from a spray gun. Types of wood finishes include: Oils,Waxes, Paints, Lacquers and Varnish.

• It is important not to breath in fumes from any wood finishes and do not allow finishes and solvents to touch your eyes or skin.

Step 15: Making the Beater

Action Tools/ Equipment Processes/Techniques Safety You will be given length of

dowel and a bouncy ball. 300mm length of

dowel Bouncy ball

Drill a hole in the bouncy ball using the pedestal drill.

Pedestal Drill Dowel Ball

Set the pedestal drill to 10mm Place the ball in the clamp Bring down the drill bit using the handle

Attach the dowel to the ball PVA glue Put a small amount of PVA glue in the hole of the bouncy ball.

Insert the dowel into the bouncy ball hole

Leave your beater to dry.

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Tongue drum teacher