Making an Alphorn
“I sound my barbaric yawp over the rooftops of the world” , from Tune of Myself by Walt Whitman.
Spring 2020:
Alphorns, also referred to as Alpine Horns or Alpenhorns, make a heat, wealthy, sonorous, mysterious sound; their historical past is outdated and married to the Alps. They’re stunning items of woodworking additionally. I wished to play one, so I got down to construct one. I constructed the Alphorns proven under in my workshop in Wisconsin, USA.
Web page Contents:
1. Background info on Alphorns
2. Images of my completed Alphorn
3. Alphorn and mouthpiece dimensional drawings
4. Construct log of constructing alphorn mouthpieces
5. Full construct log of my first Alphorn. This Alphorn is fabricated from Sitka Spruce, is a one-piece alphorn, and is absolutely wrapped with picket reed wrapping.
6. Construct log of my second alphorn. The intent of this 2nd alphorn was to construct an alphorn from very cheap, available building lumber, and in addition to construct a light-weight horn that breaks down into 3 sections for simpler transportation.
These are the 2 Alphorns that I constructed. Construct-logs for each of those alphorns are on this web page.
Alphorns being performed in Switzerland; picture from Wikipedia.
Right here is the Alphorn that I constructed. The construct log for this Alphorn is under. Photograph taken March 21 at Ausblick Ski Hill in Wisconsin, USA.
That is me and the selfmade Alphorn I constructed; seeing an individual within the picture helps present simply how large these horns are.
I constructed my Alphorn to the tune of F. It’s roughly 12′ 3″ lengthy.
I constructed my alphorn of Sitka Spruce, with Black Walnut, Maple, and Cherry trim rings. On the bell, I painted native Spring wildflowers.
Mouthpiece finish of my Alphorn
I made a decision to construct an Alphorn tuned to F (approx. 373cm lengthy or 12′ – 3″ lengthy). The mouthpiece sizes appear to vary from much like a trombone mouthpiece on the massive finish, to much like a French Horn mouthpiece on the smaller finish. The smaller mouthpieces work higher to play the melodies within the increased register. For reference the size of tubing in a trombone is about 9 ft. Concerning the form of the Alphorn bell, I drew this from pictures. I nonetheless had questions on the size of the primary trunk of an alphorn, so I wrote an e-mail to an Alphorn participant, William Hopson, who gave me the good recommendation to construct it a bit lengthy after which trim it all the way down to tune it. The drawings under are a results of my analysis.
Overview Video of the Development of this Alphorn
Dimensional drawings and an in depth construct log for this alphorn, could also be discovered additional down on this web page.
A Transient Historical past of Alphorns
These stunning horns have been constructed from spruce timber rising excessive within the Alps and have been utilized by Alpine shepherds 2000 years in the past to speak with different individuals and to name grazing animals, and in addition to make music. Way back, builders would select a excessive mountain tree that grew out of a steep mountainside. After rising out from the mountainside, the tree would flip and develop vertically towards the solar, and the form of the tree was utilized by the early builders of Alphorns to make the form of the horn. The timber have been cut up in half, carved out, the halves reattached, and the horn made. Alphorn enjoying declined within the late 1700’s and early 1800’s as they have been wanted much less for communication. Efforts have been made in Switzerland through the 1800’s to advertise the Alphorn resulting from its cultural significance, and the Alphorn has seen a resurgence within the final hundred and fifty years, and particularly the final 40 years. They are often bought on-line or at some shops, and there are Alphorn enjoying workshops and festivals in Europe and North America. It could appear that F is the commonest pitch for alphorns in North America, whereas F# is widespread in Europe.
Alphorn Drawings by a Novice Alphorn Builder
Fashionable Alphorns obtainable for buy , are available three or 4 sections that one assembles into the Alphorn previous to enjoying it. This makes transporting the Alphorn a lot simpler. Mine will probably be a one piece Alphorn!
These are decidedly European devices, so I used the metric system in my drawings. I don’t declare to be an authority on Alphorns, that is merely my documentation of the one which I constructed. In my notes under I exploit each metric and imperial notation, apologies for any confusion.
Be happy to make use of these drawings for constructing an Alphorn in your personal use, contact jason@argobuilder.com for permission to breed these drawings for any goal apart from constructing an Alphorn in your personal use.
Alphorn, or Alpen Horn, or Alpine Horn, basic association drawing with Alphorn dimensions.
Alphorn mouthpiece dimensions. One could make an infinite vary of mouthpieces with various cup diameters, cup depth, cup form, rim width and form, bore diameter and form. The bore ought to scale back to round 3/16″ on the base of the bowl, after which broaden out to five/16
or so on the discharge finish of the mouthpiece, however with my instruments, I’m restricted to straight bores when making the mouthpiece from wooden. I’ve made three to date, all pictured additional under on this web page. Smaller diameter mouthpieces will help enjoying increased notes, and bigger diameter mouthpieces might be higher fitted to decrease notes.
See improved mouthpiece drawings under! Together with tapered internal bore. I believe the tapered internal bore performs higher and sounds higher.
Right here is my newest 20mm alphorn mouthpiece design, together with a tapered internal bore.
Right here is my newest 18mm alphorn mouthpiece design, together with a tapered internal bore.
GLUE: I’ll use Titebond III glue for many of this mission. In three locations, I’ll use a 2-part epoxy: I’ll use two-part epoxy to attach the top rings to the bell, to attach the bell to the lengthy trunk, and to attach the foot to the bell.
My information to constructing an alphorn is under, however first, a piece on making mouthpieces
Making an Alphorn Mouthpiece
Right here I’ll present examples of straightforward picket mouthpieces and in addition plastic ones.
Maple is a conventional wooden for the making of an Alpenhorn mouthpiece. I had lower down a tough maple that grew on my property in Thiensville, Wisconsin, about eighteen years in the past, and I nonetheless had some sections of the trunk left. I made this mouthpiece from that tree.
Laborious Maple clean , lower right into a tough octagon earlier than turning.
The beginning of turning the Alphorn mouthpiece.
Checking dimensions with a caliper, from drawing to the piece.
Checking dimensions from the drawing vs the work piece.
The Alphorn mouth piece is coming alongside.
Right here is the rough-turned and tough sanded Alphorn mouthpiece, faraway from the lathe.
Drilling the bore by the stem of the mouthpiece
I performed my Alphorn and the first mouthpiece labored properly, however getting used to a trombone mouthpiece I wished one a bit larger so I made considered one of cherry much like a trombone mouthpiece. It isn’t an enormous mission to make these mouthpieces so I’ll make a couple of and take a look at them.
Completed cherry Alphorn mouthpiece, a bit larger than the maple one I made.
I’ve been experimenting with making and enjoying mouthpieces of various cup diameters, depth, inside form, bore diameter, and rim width/form. I’ve wound up to date with small, medium, and enormous variations of the mouth piece. Notice that the outer form of the cup doesn’t mirror what the internal cup form is….
Experimentation: 3D printed Alphorn Mouthpieces
Designed on Fusion360 and printed in PETG on a Prusa MK3 i3 3D printer. These are 100% stable PETG and have tapered internal bores as proven within the drawings above.
3D Printed Alphorn Mouthpiece. Printed in PETG materials.
Listed below are a few of my completed 3D printed PETG mouthpieces. The massive opne is 25mm, adopted by my favourite sizes: 18mm and 20mm.
These are drawings are Copyright Jason Talbot Jan 2021. Please be happy to make use of them for making a mouthpiece in your personal private use, these drawings usually are not for use for making mouthpieces for resale air any industrial goal.
| talbot_18mm_alphorn_mouthpiece_v3.stl |
| talbot_20mm_alphorn_mouthpiece_v3.stl |
Beneath are two construct logs of Alphorn initiatives.
1. The primary is a Sitka Spruce Alphorn wrapped in wooden reed. This can be a one piece alphorn.
2. The second construct log is for an Alphorn constructed out of low value SPF (Spruce, Pine or Fir) building lumber. This alphorn is not going to be wrapped in wooden reed and will probably be lower into segments in order that it may be disassembled.
Construct Log 1 of two: Making an Alphorn Out of Sitka Spruce and Wrapped with Wood Reeds:
Sitka Spruce
The tree itself is awe-inspiring. I airplane and carve and lower this wooden with the utmost respect, and have solely used it for making such transcendental issues as sailboat masts and spars, and musical devices. The Sitka Spruce grows within the Pacific Northwest of the USA and Canada. The Sitka Spruce is without doubt one of the few species on earth recognized to develop over 300 ft tall (over 90m). The forest of Sitka Spruce has been vastly diminished by logging, however on a optimistic notice, it’s thought of a “species of least concern” concerning potential for extinction of the species. The biggest of those timber have been lower down up to now earlier than the giants could possibly be measured. The older timber don’t even have branches on the decrease 100 ft of the trunk. The Queets Spruce in Olympic Nationwide Park is 450 years outdated, and a few Sitka Spruces are over 700 years outdated. All wooden is particular wooden in its personal means, and this additionally may be very particular wooden.
Sitka Spruce, rising in Olympic Nationwide Park.
….and so, somberly, we attain the half the place the tree (not crucial the tree within the image) has been chopped down and milled into lumber for our use. I’ll flip this into an Alphorn, which is a noble finish. I want I could possibly be of such a fantastic use after I chew the mud. I might be pleased to return to the soil, and to do as Whitman suggests: from Leaves of Grass: “I bequeath myself to the grime to develop from the grass I really like, If you would like me once more search for me underneath your boot-soles.” All timber are particular, and these Spruce are particular even amongst all timber; I’ll benefit from the wooden.
Two 4/4 x 6 x 17′ tough sawn Sitka Spruce boards from McCormick Lumber in Madison Wisconsin. Dimensions are 1.0″ x 6″ x 17′. These are completely straight, straight and vertical grained board with no knots. I constructed the alphorn from these two boards, plus a 4/4 x 6″ x 7foot board I had within the basement, on the finish of the mission I used to be left with a 4/4 x 4 x 8 foot piece of Sitka Spruce remaining from this uncooked materials.
Right here you possibly can see why that is such a sought-after wooden; tight, vertical, straight grain, with no knots over a 17′ to twenty’ size.
Making the Alpenhorn Bell
The bell will probably be constructed of Sitka spruce from laminated sections as proven under. After gluing the items collectively, I’ll carve them to spherical.
Sitka spruce items , lower to form to build-up the laminations wanted to make the Alpenhorn bell.
Utilizing many clamps….
This is what slightly over one half of the bell laminations appear to be stacked up.
Finish-view of 1 half of the small finish of the bell, tough on the preliminary glue-up stage.
Listed below are each halves of the Alphorn bell on the stage of preliminary lamination glue-up.
Finish-view of 1 half of the massive finish of the bell, on the preliminary glue-up stage.
Giant finish of bell, not glued up but, however exhibiting that the halves match properly.
I drew the road for the top of the bell and lower it utilizing the Japanese pull noticed. Do that rigorously.
Trimming the small diameter finish of the bell to size.
I made these templates out of 1/4” plywood. I’ll use them to hint the bell OD and ID onto the wooden.
With the 2 halves clamped (however not glued!) collectively good, I traced the ultimate bell form onto the ends utilizing the templates I had made.
Then I used a mortise gage to mark the wall thickness alongside the size.
Carving out the within of the Alphorn bell with chisel and mallet! I had an odd variety of laminations, so this “half” of the bell is lower than half of the bell.
I’ve left the OD uncarved as I carve out the ID, in try to take care of power of the wooden as I chisel away from the ID. The power of the chisel blows will shock an individual, as this Sitka is robust. WATCH THE TREE GROWTH LINES and perceive that that woods splits alongside the grain. After a short while carving, an individual will understad this and use it to their profit. I’m utilizing my straight chisels for nearly all of this carving as a result of straight chisels are soooo a lot simpler to sharpen. As I get nearer to the completed ID I’ll use my curved chisel.
Nonetheless carving, carving, carving. Getting there. Quickly I’ll begin tough carving the surface of the bell.
Now I’ve to sand them clean, however first I’ll carve the outer floor of the bell.
This half of the bell is flipped over and I’ll begin tough carving the surface with a chisel.
Chipping away on the outer floor of the Alphorn bell.
Sitka is fairly robust, particularly for a softwood tree. Working with sharp instruments is a necessity. Right now I took a break to sharpen chisels.
With chisel carving accomplished, I’ll now clean the outside of the bell with a Shinto Rasp. The Shinto rasp is a tremendous instrument.
Right here is one half of the Alpenhorn bell, with ID tough carved , and OD carved and rasped clean.
Now I’ll begin carving the surface of the opposite half. One difficult side of carving this bell is holding it tight in order that it doesn’t transfer as one carves it. Notice the help blocks that I’ve screwed into the work desk. After implementing this technique of securing the workpiece, the carving grew to become extra environment friendly.
Listed below are the 2 Alphorn Bell halves, resting collectively. Subsequent I’ll sand the insides, after which I’ll glue the halves collectively.
I used a 3″ diameter x 3″ lengthy sanding drum, chucked in a 1/2″ handheld electrical drill to sand the ID of the bell.
Titebond III glue utilized to each halves of the alphorn bell.
Second of fact! It match collectively properly, this was a giant second within the mission.
I chosen a pleasant native wooden, a darkish hardwood, Black Walnut, for the ring on the finish of the bell. This can be a 10.5″ x 10.5″ x 3/4″ glue-up.
The outside of the bell has been tough sanded with a random orbit sander.
The ring meeting on the top of the bell will include two hardwood rings, a Black Walnut ring will match as much as the face of the endgrain of the bell, and the laborious Maple ring will match over the OD of the top of the bell.
Lower the OD of the ring, then I used a router to spherical over the sting, then used a sabre noticed to chop out the ID.
Maple ring prepared for set up
Black Walnut ring, prepared for set up.
I used a two half epoxy to attach the rings to the bell and to one another. It is robust to see within the picture however the small finish of the bell is resting up towards a picket brace to carry it in alignment in order that the large face of the bell is laying flat on the ring. You’ll want to put on latex gloves when working with epoxy.
Utilizing a rasp to form the flare of the ring on the finish of the bell.
Sanding, sanding, sanding…
Tough sanding is all accomplished.
I measured out the approximate measurement of the area obtainable for artowork on the highest of the bell, and arrived at approx 8″ Lengthy x 2″ on the slim finish x 5″ on the huge finish. I sketched out that space on a chunk of paper after which sketched out the floral theme I’ll use. I drew springtime wildflowers which can be native to my dwelling right here in Wisconsin; from left to proper: Wooden Violets, Trillium, and Buttercups.
On the massive finish of the trunk and the small finish of the bell, I’ll epoxy Black Walnut ring flanges over the O.D. for reinforcement of that joint. Listed below are the rings in contruction.
Hardwood flange dry-fit on the top of the bell.
Making the lengthy trunk of the Alpenhorn
IMPORTANT NOTE: I made the trunk of the Alphorn 6″ (15.24cm) LONGER than proven on the drawing. The additional size was added to the mouthpiece finish of the trunk. If I might have added the additional size to the bell-end of the trunk, the diameter wouldn’t have been right the place it meets the bell. I’ll trim the size of the mouthpiece finish later when the horn is assembled in an try and tune the horn to F, hopefully this works.
4/4 x 6″ x 10.5 foot tough sawn Sitka spruce being ripped into three 2″ huge items. I lower another 2″ huge strip from a second board of Sitka Spruce.
Then I rigorously ripped every of these 4 items down the center to wind up with eight 1/2″ x 2″ x 10.5′ items.
I’ll name these items that make up the trunk of the Alphorn, Staves. At this level I floor planed the staves to exactly 1cm thickness.
The staves are ripped to 43mm width. So now I’ve eight 10mm x 43mm full-length staves.
To chop the “birdsmouth” into the staves, rigorously set the depth of the tablesaw, and thoroughly set the angle to 45deg and the fence in place. Take a look at the cuts first on a chunk of scrap wooden lower to the very same dimensions because the clean staves.
Listed below are the eight staves with the birdsmouths lower in.
I used an extended straight-edge to attract out the taper onto the primary stave.
I lower the taper into the stave utilizing a Sabre Noticed after which traced out the taper on the remaining 7 staves.
Be attentive to not make the staves to large or too small. The scale within the drawing are actual; in case your staves are a bit to large the internal bore of your alphorn will probably be to large. Double test and dry suit your staves and you may shave them a bit smaller if wanted.
Listed below are all eight staves with the birdsmouths lower and the staves tapered to form.
I lower three cradles from scrap plywood to help in assembling the birdsmouth staves. I made positive they have been completely degree and straight.
NOW, dry match the staves collectively and maintain them along with zip ties. Examine that the OD of the assembled staves is right. You may nonetheless shave down the staves at this level to scale back the OD, however you can not make it larger.
First two staves of the birdsmouth Alphorn trunk glued collectively. Use ample glue and work quick!
Three staves in place.
The staves are vertical on both aspect. I made an internal help circle to assist place the ultimate staves on prime, you possibly can see this within the subsequent picture, under.
I made the internal help circle from scrap wooden together with slightly deal with to make it simple to retrieve, and can take away it as soon as all of the items are locked in place.
Utilizing zip ties to clamp the items collectively. Some jostling and pounding of the staves is important to ensure they’re all seated within the birdsmouths. I’m working down rapidly with the zip ties from the massive finish to the small finish.
The trunk of the Alphorn is glued up utilizing the birdsmouth method. I pushed a humid rag by the bore to take away any glue blobs. I’ll let it dry a great and very long time, after which will get to work planing the OD spherical.
I used the Japanese pull noticed to trim the large finish of the trunk to size.
I let the glue dry a full 24hrs after which planed used a airplane to spherical off the Alphorn trunk.
Birdsmouth Alphorn predominant trunk, planed to spherical, and sanded.
The completed partitions of my alphorn are 5mm to 9mm thick.
The massive finish of the trunk and the small finish of the bell, will each be fitted with hardwood ring flanges on their outer diameters. These will probably be epoxied on, and can in flip be epoxied collectively to connect the trunk to the bell. Listed below are the Black walnut flanges being made.
Hardwood flange, dry-fit on the O.D. of the massive finish of the Alphorn trunk, the place it should meet the bell.
Attaching the Bell to the Trunk
First I used two half epoxy glue to attach on the hardwood flanges to the trunk and bell. You’ll want to put on latex gloves when working with epoxy.
I let the epoxy on the flanges remedy for about an hour. At that time it was properly set however by no means absolutely cured. This was the purpose I wished to attach the trunk to the bell, as I’ll get a great chemical epoxy bond on all faces of the epoxied joint. I gathered up a bunch of spring clamps. See the plastic covers on the jaws of the spring clamps? Take these off beforehand….they have been too slippery and stored permitting the clamps to slide off, so I needed to take away them in a rush through the glue-up.
Alpenhorn bell epoxied to the trunk utilizing a flanged joint.
So for the primary time I obtained a view of the entire alphorn! Subsequent I’ll tune it by slicing down the size at the mouthpiece finish of the horn.
Tuning an Alphorn
I made a decision to make an Alphorn tuned to F. F# can also be in style, however when listening to most Alphorn tunes on youtube, it appeared most have been tuned to F. The one solution to tune an Alphorn is to make it longer or shorter. One can decrease to tuned-pitch of an alphorn by inserted an extender into the mouthpiece bore after which inserting your mouthpiece into the extender. To my information there may be not a solution to make the tuned pitch of an alphorn increased, apart from by slicing it all the way down to a shorter size. When one performs an alphorn, the variation in pitch comes from the embouchure and frequency of vibration and airflow created by the gamers mouth and lungs, however the pure tuned pitch of the instrument is about by the maker throughout tuning, by slicing it to size. For that reason, the instrument is made a bit longer than wanted in order that it may be trimmed down in size to tune it.
I used to be curious if the pitch can be modified by attaching the bell (I assume the additional size of the bell will decrease the pitch a bit), so after the trunk was glued up, I took it exterior and performed simply the trunk. I used a digital tuner and located the trunk itself performed a G! In order it stood the horn is just one step excessive with simply the trunk. This made me nervous, as making the tune decrease would require including size which I can’t do. After I connect the bell, I’ll play it once more and hope that the addition of the bell lowers the general pitch by a not less than an entire notice.
Effectively, I connected the bell and it made the Alphorn one full notice decrease in pitch, I used to be very glad for this. I trimmed an inch (2.54cm) to get it to an F.
Digital tuner apps might be downloaded free of charge in your telephone, or one can buy a digital tuner from a music retailer, or one might use a pitch-pipe or a tuning fork to create the pitch of F. I used an app that I already had on my telephone. Listed below are the display captures from three octaves of F on my Alphorn (from excessive F to low F). The bottom F is a bit low.
The Mouthpiece-Finish-Ring, the Foot, and Wrapping the Alphorn with Rattan
I discovered this good thick stable piece of scrap Cherry within the store, it’s the heart drop from a gap noticed lower from a mission a pair years in the past. I’ll use it to make the little reinforcing ring close to the mouthpiece.
Boring out the ring utilizing the drill press, the one drill bit I had that was shut in measurement to what I wanted was a spade bit….not the most effective drill bit for this sort of lower in a bit of hardwood, but it surely’s what I had. I used to be not less than sharp, and it labored.
The opening from the drill-bit was too small, so I used slightly drum sander chucked within the drill press to enlarge the ID to suit the Alpenhorn. I made a decision I wished this ring to be about 75mm (3″) down from the inlet finish of the horn, which is a bit farther down that proven on my drawing.
Subsequent, I used a bandsaw to trim the OD of the ring to about 44mm. I forgot to get a photograph of that step.
I used the drum-sander chucked in a hand drill to carve the concave curve into the ring, then I handsanded the piece down and rounded the sides.
Completed ring, fabricated from stable cherry, for the inlet finish of the Alphorn.
Right here is the ring glued in place with Tightbond III glue.
I rasped and sanded the flanges the place the bell attaches to the trunk.
The foot of the Alphorn
The Alphorn is fitted with a small foot on the underside of the bell, which lifts the horn out of the grass to guard the bell and ensure the sound can exit the horn unobstructed from low floor cowl.
I rigorously lower a template out of cardstock and made positive that the curve of the highest of the foot matched the bell completely.
I made the foot from 4/4 Sitka Spruce, with Black Walnut pads on the underside. The cradle of the foot is lower at an angle in order that the ft will probably be degree with the bottom when the horn is performed.
The foot is adhered to the bell with two-part epoxy glue.
I rounded off the sharp edges of the foot pads.
Wrapping the Alphorn with Wooden Reed
I’ll wrap the trunk of my Alphorn with 1/4″ half oval basket reed. This fibrous materials may be very sturdy in rigidity. Many points of constructing an alphorn have been new for me, together with this wrapping step. It took for much longer that I anticipated; holding the joints good and tight prevented me from simply spinning the trunk rapidly, and lots of, many reeds and clamping was wanted, as every reed solely will get about 4-10″ of protection down the barrel of the Alphorn.
That is 1/4″ Flat Oval Reed, which is used for basket making or chair-wicker, that is what I’ll use to wrap my Alphorn.
The reed arrives in coiled up bundles. Each bit is 8-14′ lengthy. (240-430cm)
I began wrapping the Alphorn trunk on the mouthpiece finish, simply down from the hardwood ring. Discover the place the wrapping simply begins on the left that I carved an extended taper into the reed to start out the wrap. I glued and clamped this down with a spring clamp and began wrapping. I watered down Titebond III glue utilized it to the OD with a toothbrush previous to wrapping on the rattan. I utilized about 5” of glue at a time. I do not need messy blobs of glue squeezing out onto the OD of those wraps, It could be a nightmare to attempt an sand the surface of those wraps whereas sustaining their curved profile. The watered down glue has labored excellent.
This can be a picture of a 14 foot (430cm) size of reed wrapped across the slim finish of the Alpenhorn. Because the diameter will get bigger the horizontal protection of every size of rattan will lower. One learns many issues constructing an Alphorn, and a type of issues is simply what number of splices of reed wrapping it takes to wrap an Alphorn.
The spring clamp is holding the beginning finish of the rattan. Right here I’m making use of watered down glue with the toothbrush on a piece of the trunk previous to wrapping that part.
The clamp on the left is holding the beginning finish of the rattan wrap, the clamp on the fitting is the top of the size of the piece of rattan. I’m utilizing spring clamps which I depart in place for an hour, after which I splice on the following piece and transfer ahead.
For the splice I taper down the reed from the highest of the reed to the underside on each items to be joined, then I exploit Titebond III (not watered down for the first inch of the wrap, and clamp the splice joint for an hour earlier than unclamping. In the course of this picture you possibly can see a splice of the reeds. There will probably be extra of those than I believed, as every reed solely will get you 6-10″ of distance alongside the horn size. I’m finding all of the splice joints on the underside of the Alphorn trunk.
I noticed some horns with a brief part of wrapping on the small finish of the bell, and I preferred the look of that, so I did that. The spring clamps on the backside of the image usually are not getting used to clamp the walnut flanges collectively, they’re getting used to press the slim forefront of tapered rattan wrapping towards the trunk to maintain it from transferring. I situated the top of the wrapping on the underside of the bell the place it is not going to be seen.
The diameter exceeded to jaw capability of the spring-clamps, so at this level I’m utilizing adjustable c-clamps. You may see the everyday protection I get from every reed. The length-wise protection is getting shorter and shorter because the diameter will increase.
Whew, accomplished wrapping the Alphorn tube. Because the diameter obtained bigger the horizontal protection per strip of reed obtained smaller and smaller. I wound up utilizing 32 particular person strips of reed which have been about 390 ft lengthy mixed (approx 12′ lengthy every).
Varnishing the Alphorn
The skin of the Alphorn will probably be varnished, together with the within of the bell so far as I can attain. The ID of the bore will probably be soaked with Danish Oil later.
- I did I last sanding of the Alpenhorn previous to making use of finishes.
- First , II cleared out the entire space and cleared off the desk prime. Then I blew out the bore of the alphorn with an air-compressor
- Then I dismissed the desk and swept the ground.
- With all that mud kicked up into the air I waited half and hour for it to settle and got here again and vacuumed off the desk prime and the alphorn itself, together with as far into the bell as I might attain.
Remaining little little bit of sanding.
I planed down the top of the stick of wooden and used it to carry the small finish of the Alphorn throughout ending.
I’ll end the surface of the horn with Spar Varnish. That is precise common spar varnish, not one of many many sorts that has this or that polyurethane and so on… Simply precise spar varnish.
I varnished the bell first, in and out, then I flipped the Alphorn over and rested the large finish within the cradle proven within the picture. I varnished the underside of the trunk first, then flipped it again over onto its foot and varnished the highest.
Even the primary coat of varnish brings out good coloration and depth of the wooden and reed. After six coats, I wound up with a pleasant heat tone, and shiny floor. Photos of the completed horn are on the backside of the web page under.
Trying down the Alpenhorn after the primary coat of varnish.
I sanded the Alphorn flippantly, after which vacuumed the mud away, between coats.
Right here she is after 4 coats, two extra to go, however the last two coats will probably be after I paint the bell.
Portray an Alphorn Bell
Portray onto naked wooden might be messy, and the paint can wick into the wooden past the place the painter needs the paint to go. I began portray the bell after 4 coats of varnish, and after portray I’ll apply additional coats of varnish over the paint.
I’ll use modelers enamel paint for portray the bell.
First, I sanded down down the varnish to supply a great floor for the enamel to stick to. Right here I’m portray on a phrase in script.
I sketched the define of my portray on a chunk of paper, then I laid the paper on the bell and traced the strains whereas urgent into the wooden with a ballpoint pen. The pen didn’t mark the wooden, however I pressed laborious sufficient to go away an indent within the wooden to assist me with portray.
Right here is my sketch, after tracing alongside it with a ballpoint pen to indent the define into the wooden under.
I had the first colours and made my inexperienced and purple by mixing colours in bottle caps.
Right here is a photograph of the portray in progress. The white and yellow will want a pair coats. The varnish was sanded down to supply a great floor for adhesion of the paint.
When I’m accomplished portray the bell, I’ll apply two extra coats of spar varnish.
Accomplished Alphorn bell portray. The flowers are all native native wildflowers that bloom in Spring. The white one is a Trillium, the purple ones are the State flower of Wisconsin, Wooden Violets, and the yellow ones are Buttercups.
Oiling the inside of the Alpenhorn
I flooded the inside of the Alphorn with penetrating wooden oil. The aim is to guard the inside of the horn from moisture.
I carved a tapered bung to plug the mouthpiece finish, previous to filling the horn with oil.
Right here the Alphorn has been stuffed with 1 gallon penetrating wooden oil. I turned the horn over and sloshed the oil throughout inside. 1 gallon will not be sufficient to truly fill the horn so one must rotate it round to be able to get good inside protection. I then eliminated the bung and poured the oil out the mouthpiece finish.
Images of the Completed Alphorn
Handmade Alphorn, constructed of Sitka Spruce, in Wisconsin in March and April of 2020.
I completely love the way in which the Alphorn sounds, and I really like enjoying it!
Construct Log 2 of two: Making an Alphorn from Frequent Spruce/Pine/Fir Development Lumber
Right here is a photograph of the bell of my second alpenhorn, the construct log for which , is under.
Alphorns have been initially devices of working farmers. These weren’t the high-brow devices performed in royal chambers or nationwide opera homes (although they’re now!, which is nice). On this spirit, I got down to make a lower-cost alphorn from humble building lumber. My first alphorn is wrapped in wooden reed and in addition can’t be disassembled. I’m constructing this pine alphorn with the intent of making a light-weight and moveable Alphorn, so I cannot wrap it and I’ll chop it into segments that may be disassembled for transportation.
This alphorn will probably be constructed utilizing comparable building strategies, and to the identical dimensions, because the Alphorn above. In gentle of that, I cannot duplicate all of the element within the construct log above. This 2nd construct log will probably be shorter and can solely embrace element on new building particulars such because the section joints.
RAW MATERIALS FOR THIS ALPHORN: I’ll use “SPF” building lumber for this construct. This stands for “Spruce Pine or Fir” and might be any of these woods. These are building lumber and have a knots. I took time and picked the perfect boards I might discover within the pile. The 2×4 and 2×6 on the retailer have been pine and the 2x10s have been fir. This lumber value $59.00 together with tax.
Uncooked supplies for my 2nd alphorn: One 2x6x12 (38mm x 140mm x 3658mm), One 2x4x12 (38mm x 89mm x 3658mm), and Two 2x10x6 (38mm x 235mm x 1829mm).
Slicing the items that may turn out to be the staves of the Alphorn trunk. These have been lower from the 12′ lengthy 2×6 and 2×4 lumber. Fastidiously make your cuts to take away as many knots as attainable.
I lower the staves blanks with the grain in thoughts, to wind up with staves with as vertical a grain as attainable. Orient your cuts to realize this. Right here you possibly can see that I obtained a decently vertical grain, although within the stave on the underside the grain will not be pretty much as good. I discover that the final couple inches of the birdsmouth lower can waver a bit, and these imperfect birdsmouth ends might be seen on this picture. I lower of a little bit of each ends off when slicing the stave to size to take away these imperfect ends.
This image exhibits the lengthy tapers.
Glued up birdsmouth joinery Alphorn trunk. This picture is deceiving I as there may be really extra taper to the trunk than what seems within the picture, that is as a result of small finish being so near the digital camera making it look larger, vs the large finish which is much away making it look smaller. The items went collectively properly. It’s all the time a messy affair assembling these and it’s difficult. Be decided and work intentionally and do not hand over if the items flop and fall round. I did this solo, but when it’s your first time assembling one, you would possibly profit from a second particular person serving to. It’s a bit hectic because the glue is drying. I began on the large finish, obtained the joints in place, rapidly threw on a zipper tie, after which labored my means all the way down to the thin finish with a zipper tie each foot. Then I got here again and added further zip ties each 6 inches.
I lower little wedges and pounded them underneath the zip ties to shut up any gaps.
Tough planed trunk of the Alphorn. Some gaps within the birdsmouth joints are seen, however I used to be glad to see them not less than stuffed with cured glue.
There have been 4 unfastened/empty knot holes within the alphorn trunk. I drilled them out with a 3/4″ forstner bit and plugged them with plugs that I had lower from the identical actual materials, with the grain going the identical path.
Determined to make a template of the aspect view of the bell. I drew the form barely completely different from my drawings above. On the higher curve , I stored the bell narrower till nearer to the bell finish, after which flared it up extra.
I traced out 6 full-size bell items onto the 2×10
I planed down each side of every 2×10 on my floor planer to flatten out the development lumber. There’s solely slightly that may be planed off earlier than the items will get too skinny to make the complete OD of the bell, however planing them will assist flatted them out for a great glue bond. This image is after planing, and in addition after I sketched the plan-view form of the bell onto the items.
Carving away the wooden of the bell is a big quantity of labor, so eradicating any wooden now could be a profit. When trying on the plan view of the form of the bell, it was clear that I might chop the outer items quick as proven.
Listed below are the 2 halves, individually glued collectively into every half. Clamps eliminated. I lower out some materials from the innermost slab, to make carving faster. Now I’ll carve them, then glue them collectively to kind the completed bell.
November 2022 replace: I took a yr and a half off of engaged on this mission, however I’m again at it!!! Began carving the bell final month and right this moment obtained it glued up.
Tough carving the bell with a chisel and mallet.
I used a really coarse sanding wheel on my proper angle grinder to tough sand the within and out of doors of the bell halves to their completed form.
Clamping the bell collectively. Glue up with Titebond III glue.
I wanted slightly localized clamping pressure on the prime of the bell finish, and this picture exhibits how I did that.
Sanding bell with 80 grit sandpaper on a random orbit sander
Tracing hardwood flange on a chunk of three/4″ thick stable hickory.
Bell progress and in addition the top of the primary trunk is proven within the picture.
This will probably be a extra easy trying horn than the primary one I constructed. The bell finish is not going to have any hardwood rings, however may have a single wrap of picket reed. Right here is a photograph of gluing on the reed.
Measured the complete size and divided by three and now slicing the sections with a thin-kerf pull-saw.
Listed below are the three sections of the alphorn. The bigger diameter, shorter part, may have the bell connected to it, after which it is going to be the identical size because the others.
I normal an alphorn foot from a white-tailed deer antler that I discovered close to our home. I epoxied a reinforcing oak pin into it, and I floor a radius into it to match the horn.
Subsequent I used epoxy glue to attach stable Hickory flanges across the outer diameters of the bell and adjoining trunk piece. As soon as these cured, I then glued them collectively to connect the bell to the trunk.
Epoxy glue was used to attach the Hickory flanges across the tube components, after which additionally to attach the bell to the tube. I discovered it very helpful to clamp a picket stick within the bench clamp, after which to place the tube over the stick to be able to preserve it upright.
Hickory flange, epoxied on, and I sanded the sides spherical.
I clamped the sections within the right orientation and drilled 4 holes for #10 wooden screws.
Epoxied the foot onto the bell. There’s a pin epoxied into the middle of the foot and into the bell additionally.
Present standing of the three sections. Now I’ll apply the gloss end and paint the bell.
Completed flange joint. Notice that I offset the flange joint a bit, which creates a “Socket” kind joint for ease of meeting and added power.
Right here is the opposite part exhibiting the socket finish of the part joint.
Right here is the assembled joint, together with a 1/16″ rubber gasket. I painted little flowers to permit simple visible alignment when assembling the sections. The joint is kind of tight even with out the 1/16″ round gasket, so I’ll check the horn with and with out this gasket.
Do-it-yourself alphorn in 3 sections.
Methods to tune an Alphorn!
Methods to tune an Alphorn:
1. Construct the Alphorn a bit too lengthy
2. Get a tuner and tune it to F or F# relying in your desire, by rigorously slicing the the mouthpiece finish of the horn shorter and shorter until it’s in tune. Shortening the horn brings the pitch increased. The one solution to decrease the pitch is to make the horn longer, which is tough to do, so watch out with this step.
Alphorn by slicing it shorter. I used a pointy, fantastic toothed Japanese pull-saw.
Remaining Finishes to My Second Alphorn:
Listed below are broomcorn stalks. I’ve soaked the ends which I’ll plait, in sizzling water for an hour or so. I’m slicing off the tassle-ends of the broom corn (the tassles can be the broom materials , which I do not want).
Right here is the broom corn plaited (woven) on. Compressing the stalks on the ends makes them flare out as proven within the picture.
I exploit pipe clamps to compress the stalks tight towards the horn. These will dry firmly in place, after which when dry, I’ll trim them off.
And right here I’ve lower the broomcorn flush with a pointy knife and eliminated the clamps.