Introduction:
This technique is used in the Amazon by some of the native people to make blow-guns. Visualize a baguette (loaf) of French bread with the ends cut off, sliced in half length wise, the center scooped out and the two halves glued back together. Because you are not confined to straight wood, you can use limbs or trunks with some very interesting bends. If you are willing to accept the sound of a constructed Didj and have access to the right equipment this is by far the simplest method of building a wooden Didj. You will need the means to bore a short center hole, a saw to cut the stock in half, length wise and a means of removing wood from the center of the two halves.
Technique:
Using a drill bit (1 1/4 to 1 1/2 in), bore/drill a hole in both ends of the stock. These holes can be as short at 3 in or as long a 12 in and can be of different lengths. The primary purpose of these holes is to establish reference points for the hollowing operation. With the holes bored, rough shape the outside of the Didj using the holes in either end as a guide. If the bell end is to be larger that the mouth you will need to draw a the correct size of the interior hole on the bell end. Once you have shaped the exterior of both the bell and mouth ends you can establish a taper from end to end. When you have roughed out the exterior, use a saw (band-saw works best) to cut the Didj in half length wise. Firmly secure the two halves to a work surface with the interior portions exposed. I use a tool called Lancelot from, yes you guessed it, King Arthur's Tools Tallahassee FL. Lancelot is a 4 1/2 in chain saw attached to an angle grinder and turning at 10,000 RPM, it eats wood faster than a thousand starving Beavers. This process can be performed with router and a half round router bit or a hand chisel. Clean out the center material remembering the two sides should resemble half of a hollow cone when complete.
!! Termites do not eat the interior of a Didj perfectly clean and even - why should you/ Leave the interior somewhat obstructed. It is helpful to scribe a line the same distance from each edge to insure that the amount of wood removed is approximately the same in both halves. Also measure the thickness of the walls before the two halves are joined so that you will have an idea as to how much exterior wood can be removed.
When the insides is complete, apply glue to the halves and clamp them together. This can be done with C clamps or strips of rubber inner tube. When the glue has cured, you can do any final shaping of the outside, sand, decorate and finish the Didj. Depending on the glue and tools you have to work with, you can play your first drone on this Didj the same day you begin it's construction.
!! It is helpful to scribe a line the same distance from each edge to insure that the amount of wood removed is approximately the same in both halves. Also, measure the wall width before the two halves are joined so that when your are shaping the outside you will have an idea as to how much exterior material can be removed.
@ Do not become attached to any piece of wood until you have completed the interior and exterior shaping because a number of things can go wrong if you are not careful.
When and if you complete the bore, the interior shaping of the bell and the exterior shaping can be done with rasp, or other similar tools. Again care must be exercised to prevent cutting into the interior chamber. Sanding, decorating and finishing are the next steps.
I hope these thoughts prove helpful. If anyone has any questions, I can be reached at bonsaii@aol.com
El Rayo
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