C: 10 1/4" D: 9 7/8" E: 9 3/4" F: 9 5/16" G: 9" A: 8 5/8" B: 8 5/16" C: 8 1/16" D: 7 3/4" E: 7 7/16" F: 7 1/16" G: 6 13/16 A: 6 716"
After all the blanks are cut to size, choose a medium grit sandpaper to take off the sharp edges and corners.
When fine tuning the upper harmonics, sanding at the ends of the arch is required. Fine tuning of harmonics will be a challenge at first but will be a worthwhile pursuit. While it is not necessary to tune the harmonics to produce a bar of adequate quality for a father/son project, the actions and reactions within a properly tuned bar will work together, rather than in opposition, for an end product that is resonant and pleasing.
For this project the tuning of the octave above the fundamental should serve as a sufficent goal. After the fundamental has been tuned, attention may be turned to tuning the overtone. To find the overtone, turn your xylophone mallet around and tap the bar with the handle while holding the bar at its nodal point. The octave may have to be tuned by ear if it does not register on the tuner. Sanding at both ends of the arch will bring the pitch down. Make sure to be mindful of the fundamental pitch, as it too may be affected by the sanding process.
Follow with the measuring and cutting of the two end pieces:
These two pieces should be machined with the ends of both end pieces angled 3 degrees. This will allow for a snug fit of the box's sides as the box tapers from the large end to the small end.
Measure and cut the botttom of the resonator box next.
Side view of the resonator box bottom:
Side view of resonator box for box bottom positioning:
Resonator box dividers may be cut next. Two dividers 1/8' in thickness should be sufficient for this project.
Handle - Left End 7 5/8" x 7 1/4" x 2 1/4" Handle - Right End 4 3/4" x 4 1/2" x 1 5/8"
Fourteen guide posts will be needed to keep the bars in alignment. Set screws with plastic screw covers will work well.
After the bar posts and bar guides are installed, braid weave the cord around the posts on both sides. The cord will provide a cushion for the bars.
The bars may now be placed on the xylophone and the instrument can be tested.
Congratulations on completing your Orff xylophone!