🖼️
The project:
A salvaged piece of 12mm plywood from a plant nursery destined for the tip, becomes a wooden drum ( Cajon) and when not in use, becomes an interesting side table. My intention was to sand and stain the plywood but after forgetting I painted the underside white some time ago, I decided to roughly sand this side and use it as the outside part instead.
- Materials:
- 12mm plywood
- 3mm plywood
- Timber off cuts for bracing and for snare attachment
- Timber screws
- Bullet head nails
- Gorilla Ultimate Wood Glue
- Scandinavian Oil
- Varnish
- Rubber Bumpers (4)
- 1 x 14" 20 strand snare wires
- Rags, sanding mask
- Alphabet stamps and stamp pads
- Tools:
- Jigsaw
- Router with rebate bit
- Sander and sandpaper
- Drill and drill bits
- Hammer
- Clamps
- Wire Cutter
- Tape measure /ruler
- Step 1:
Cut 12mm plywood as follows:
2 x 300mm x 300mm (top and bottom pieces)
3 x 300mm x 450 mm ( 2 side pieces and 1 back piece - which i had to trim down to fit in the rebated area)
Sand the plywood to give it a distressed look and to remove scuff marks.
- Step 2:
Router 3 sides of both 300mm x 300mm pieces. Router 1 long edge of two 300mm x 450mm pieces. The rebate should be 12mm wide and 6mm deep . Glue and nail top, bottom and the two side pieces together and clamp for 24hrs. No routered parts should be at the front.
- Step 3:
Trim the back piece so it fits in the rebated area and using a jigsaw, cut out a circle. Mine measures 110mm wide and is positioned about 1/4 of the way down. This is the sound hole. Sand edges until smooth and then glue the piece into place. Sit something on top to weigh it down for 24 hrs. ( nothing too heavy though). Apply two coats of varnish to the outside only.
- Step 4:
Place the plywood face down, sit the box on top and trace around the edges. Cut to size making sure it is flush with the outer edges of the box. Round the edges and sand the top corner edges of the box until it is slightly rounded. This is so the corners don't dig into your legs when playing.
- Step 5:
Place 3mm ply on top of the box and pre drill holes around the perimeter. ( Use photo of finished article to check placement) Make sure to leave about 75mm from top corners free so that the 3mm ply has slight movement when playing. Remove this ply and set aside. Attach rubber bumpers to the bottom of the box, 30mm in from each corner.
- Step 6:
Glue some timber strips to some of the inside corners for bracing and allow to dry. Cut the snare wires in half with wire cutters and cut a piece of timber to fit inner width of the box. Glue and screw two smaller pieces to each end of the back. Attach the snare wires using photo as a guide for placement.
- Step 7:
Place the wooden snare piece in the box and temporarily screw the 3mm ply in place. Put your hand through the sound hole at the back and move the snare piece around and tap on the front until you achieve the right snare sound. When happy with the sound, use a pencil to trace around the two smaller end pieces for a drilling placement guide. I placed mine on an angle facing forward so the snares rest on the ply. ( It won't work if it is not touching the front) The top of the snare wires should only be 10mm -30mm from the top as well. Remove 3mm ply again. Pre drill one hole only in each of the smaller timber pieces and screw in place from the inside making sure not to go all the way through to the outer side. You should be able to reach through the sound hole and move the timber forwards and backwards so you can have the snare sound on or off.
- Step 8:
Side view of snare placement.
- Step 9:
Ink up foam alphabet stamps to add some interest to the 3mm ply or you could leave blank. Allow to dry for 24 hours before applying two coats of Scandinavian oil. Follow instructions on label and allow some curing time. Screw the ply into place.
- Step 10:
The Cajon drum is predominantly played with the hands but I bought these cajon brushes to use with it as well. There are many other add on items like foot pedals, etc.
I think it will be a cool looking side table when not in use as well.
