WARNING: I'm not a trombone player so any ear-damage after seeing/listening to my video is at your OWN RISK ! (In fact I'm only trying to make music especially with DIY instruments)
This instrument was actually used in my legendary band "Studio KREUSCH" in which I played the bass. The one I had back than was really nice and bigger but was stolen after a performance at a local club so If you recognize my trombone....I want it back !!!! (Does this say anything about the quality?.......naah.)
This is my first instructable and English isn't my native language so any comments are very welcome so I can improve my instructable skills.
Step 1: What Do You Need?
Hmmm, what is missing here? ..Ehm, oh yes the hole saw which you can put in to your drill for making the 6,5 cm diameter "puck".
All measurements are in the metric system, while I'm Dutch. Only the tubes diameter are in inches while they sell them like that here to. (Do I smell here a conspiracy of American/English electricians?)
The rest is listed in the picture.
Step 2: Making the Bending Jig
First you'll have to make a jig for bending nice curves in your tubes.
Start with a sheet of plywood on which you draw a line in the middle so you can line it all out.
Then take the hole saw an make the "puck". Best thing with these is to start at one and in the wood and before you are trough it turn it over and drill from the other side. this way you won't splinter the edges of the wood.
Next you put a bolt into the hole in the middle of the "puck" and put it into a drill very tight so it won't turn. fasten a round file in your vice and slowly push the circle against the file. So you'll end up with a convex side of the "puck" in which the tube will fit. (of course you could do this without the drill but hey..I've more instructables to make!).
Drill a hole on the line in the plywood and attach the circle to it. Then take a piece of 3/4" tube put it against the circle and take a piece of lumber and put it on the other side so it fit snuggly. Mark the place and drill the two holes to attach the woodblock with bolds and nuts. Do the same with a piece of 5/8" tube. Make sure to line the block in a 90 degree angle with the pencil line so it will be easier to see if the tube is bend enough.
Attach the woodblock to the board.
Well this was the hardest part of this instructable so from now on it's only getting easier ;)
Step 3: Measure and Saw the Pvc Tube
If you don't have the right lengths of tube measure it and saw it to the right length.
Two pieces of 5/8", one of 40 cm, another one of 120 cm.
One piece of 3/4" of 100 cm long.
Don't forget to sand the edges.
Step 4: Bending the Tube
If you have the right lengths you can start bending.
First mark the middle of the 100 cm tube and the 120 cm tube.
This is important while you have to try to keep both ends the same length and this way you can line it with the marking on the bending jig.
Before you bend you have to put the bending spring in the tube. If you don't have these or can lent them you could try to fill the tubes with sand and close them with a cork or something (I haven't tried this with pvc but did it with thin copper tubes before and that worked).
This is to prevent the tube from braking and to prevent dents. Al tough I had some dents in my bending it isn't that of a big problem for the sound.
Don't forget to adapt the bending jig to the proper size of the tube.
Do the bending easy and make sure the curve is still in the middle all the time.
After the bending you can pull the spring out with the attached rope.
Step 5: Making the Holds
I don't know if I named them right but the pieces of wood, I called them holds, are there to keep the tube parallel and to have grip on the trombone.
First measure the distance between the middle of tubes of the 3/4" tube piece and sign this on one of the wood pieces. On these points you drill a hole with a 3/4" speed drill. Don't drill right away trough it but when the point of the drill is on the other side, turn around the wood and drill from the other side. This way you won't have any splinters on the edges.
Put the hold on the tubes.
Do the same with the thinner tube but make the hold twice. One to keep the bended tubes parallel and one to put the straight end the bended one together.
Step 6: Adding the Mouthpiece
To fit the mouthpiece on the 5/8" tube you'll have to put a connector for that size on it. That way it really fits nice on the tube. There's no glue necessary but if you want, you can use hard pvc glue.
The bigger the mouthpiece the lower the notes that are possible to make.
Step 7: Adding the Funnel
My funnel, off course in the National Dutch color orange, fits snugly in to the 5/8" tube but to secure it I glued it with hard pvc glue and taped it in place with electrician tape.
If you like it you can tape a microphone in the funnel and "tape" your music.
Here is a instructable how to make one from an ear bud
Step 8: Putting the Pieces Together
Ok, I think you can figure out how to put this together eh?
Well, the thicker tube fits over the thinner one so that won't be a problem
Put the mouthpiece against your lips and, with tight lips, blow your tunes!
Doesn't worked right away? keep practicing. Pro's talk about em brochure, it's the way you tighten or loosen your lips and it can be a tricky technique to master but with a little practicing you probably blow better than I do!