Step One

Gathering Materials

Gather the following (read the directions to estimate how much PVC to buy):

6" diameter PVC sewer drain pipe (not schedule 40)
- NOTE: You will end up cutting this down to a diameter that is slightly over 4-1/2"
4" diameter PVC sewer drain pipe (again, not schedule 40)
6 90 degree 4" diameter PVC sewer drain pipe elbows with flanges on both ends
small box of short 1/8" dia. rivets
rivet gun
drill
1/8" diameter drill bit
a saw to cut the pipe
pvc glue & primer
gum rubber (see reed section below for more information)
white duct tape

I recommend not cutting the PVC to the exact lengths I provide. I would go a little long on the measurements, shorten the segments until you get the right pitches, and then glue everything together.

If you can't find the pipe anywhere locally, you get it at US Plastic's sewer pipe section.

NOTES:

Piece 1 of the drumbone: E, C#

Piece 2 of the drumbone: G#,F#, E

Step Two

Constructing the reed

I created my reed by cutting out a section of the PVC and white duct-taped down a 12" x 12", 3/16" thick section of gum rubber that I found thanks to Drumline. I recommend purchasing McMaster-Carr's gum rubber (Part No. 87145K74). FYI to not be confused, most of the pictures displayed here show my previous reed before the gum rubber one. My reed is a segment of 16" long 4" diameter PVC pipe.

I have heard that the actual drumbone reed is made out of PVC pipe with a part sectioned off with some type of rubber riveted from the inside to the PVC. I encourage you to experiment with different materials in your reed construction.

Step Three

Constructing the first piece

Take the 6" diameter PVC pipe and cut it down to 31-3/4". Then saw in a straight line down the length of the pipe.

Curl the pipe's flaps inward until they fit snuggly around a PVC elbow.

When snug, rivet the pipe to the elbow as shown in Diagram 1-1. Space rivets roughly 2" apart around the pipe. Seal the gap between the flaps with a rivet or two; note that you will want the flaps to not face the audience if you perform with your drumbone, so seal the flaps as shown below). Then seal accordingly down the length of the pipe using rivets spaced roughly 6" apart.

Put together the elbows and internal slide segment that will fit with the reed as shown below. This will consist of three 90 degree elbows, and a 31-1/2" long, 4" diameter PVC segment for the internal part of the slide.

In order for you to put together the elbows, since they have flanges on both ends, you will need to cut two 1-1/2" long 4" diameter segments to connect the flanges as shown below. Apply PVC primer and glue to the flanges and then insert the segment beteween them.

The internal slide 31-1/2" segment of PVC should fit snugly into the flange of the elbow shown below. Apply PVC primer and glue to the flange and then insert the internal slide. Do the same for the reed on the other end of the 3-elbow structure.

Insert the internal slide part into the external slide as shown below.

Step Four

Constructing the second piece

Take the remaining 6" diameter pipe and cut a 28-3/4" segment. Then saw in a straight line down the length of the pipe.

Curl the pipe's flaps inward until it fits snuggly around a PVC elbow.

When snug, DO NOT rivet the pipe to the elbow, but instead rivet JUST the flaps together. Space rivets roughly 6" apart down the length of the flap overlap of the pipe.

Form the following as shown in Diagram 2-1 using a 28-1/2" long, 4" diameter PVC segment, two 90 degree elbows, and two 1-1/2" long, 4" diameter PVC segments.

Diagram 2-1

In order for you to fit the two elbows together, use one of the 1-1/2" PVC segments to keep them together with PVC primer and glue. Then insert the other 1-1/2" PVC segment. The first piece of the drumbone will fit into this.

The internal slide 28-1/2" segment of PVC should fit snugly into the flange of the elbow shown below. Apply PVC primer and glue to the flange and then insert the internal slide.

Insert the internal slide part in the external slide as shown below.

Diagram 2-2

Fit the first and second pieces of the drumbone together. Congratulations! You have built your very own drumbone!