How to make a miniature drum

The first stage of the miniature drum manufacturing process is making the 3 small wooden legs.

Firstly, we insert a 4mm wooden dowel into our jewellers milling machine. Next we carefully mill the required shape of the leg, using a small diamond ball cutter fo the top and a small angled knife for the rest of the body.

After this, we then sandpaper the peg until it is smooth.

Fourthly we transfer to the DREMEL multitool station, where we cut a small slot in the base of the peg to allow it to fit over the drum hoop.The final part of this stage is to prime and then paint the peg in the appropriate colour.

Stage 2 – Drum Hoops

• The first step is to take a piece of brass strip that is 12″x0.5″x.067″ and cut it to the right length.
• The second step is then to mount this strip into a special jig and drill 8 holes at the relevant spacing and height from the top.
• The third step is to then use the hand roller to convert the brass from a long rectangular strip into a circle.
• The fourth step is to solder the two ends together, to create as perfect and as complete circle as possible.
• Once this step  has been done, we then sand the whole joint before using isopropyl Alcohol to remove any grease or dirt.
• The sixth step is to prime each drum hoop. Then the fun really starts with the painting.

The second stage of the miniature drum manufacturing process is making the drum hoops. This is about the most labour intensive part of the process owing to the multiple steps and multiple coats of paint.

Each hoop requires five colours, with each colour requiring tow to three coats. And for each coat we have to apply a tiny vinyl mask – which can takes a long time to get it properly aligned!

Stage 3 – Drum Skins

The third stage of the miniature drum manufacturing process is making the drum skins. We source all our drums skins from the only remaining vellum maker in the world,  William Cowley & Son. Since 1870 this firm have been producing hand crafted vellum and parchment and were the original suppliers to the Army’s official drum maker, Henry Potter & Co.

For that reason none of our drums skins will look alike. Furthermore, The quality and authenticity of the vellum are the hallmark of our miniature drum. It is impossible at miniature scale to “lap”  the drumskin. A wooden hoop would be too flexible at this scale.

Instead, first we dampen the drum skin with water,  Next, we stretch the damp vellum tightly over the drum shell and  leave it to dry. After this, we carefully cut of the excess calfskin. The vellum sticks to the drum through the natural action of shrinkage. Finally, we add a little bit of superglue to make sure it stays firmly in place.

Stage 4 – The Drum Shell

The fourth stage of the miniature drum manufacturing process is making the drum shell.

Our process differs here from the full size drum. We use a pre-cut seamless 3″ brass tube. Next we sand the edges smooth and then mask the shell ready for printing. After this we then spray three layers of primer before adding two ayers of the background colour.

Finally, we apply a coat of lacquer

Stage 5 – The Emblazon

The fifth stage of the miniature drum manufacturing process is making the drum emblazon.

We research the regimental history, battle honours and use this to create the emblazon as a vector graphic. However, the Graphic has a hand painted feel to it because we faithfully “paint” the Grpahic using a tablet and art software. Next we get operate the background from the rest of the emblazon. This allows us to hand paint the background and get the reminder of the graphic made into a transparent decal. However our decals are unusual – they cantina full course including white and have a metallic effect.

We apply the transfer to the drum shell as a water decal – exactly as you used to apply water transfers to an old airfoil model

Stage 6 – Rope Tensioners

The fourth stage of the miniature drum manufacturing process is making the drum shell.

Our process differs here from the full size drum. We use a pre-cut seamless 3″ brass tube. Next we sand the edges smooth and then mask the shell ready for printing. After this we then spray three layers of primer before adding two ayers of the background colour.