A stave drum (or block drum) is a drum shell built from solid wood staves like a wine barrel. The staves are cut to width and the sides (bevels) are cut to an angle. Then the staves are glued together. The rough shell is cut down to the proper outside diameter, placed in another jig, and cut from the inside to the desired thickness. The shell then is cut to accurate length, checked and sanded. If a finish needs to be applied, this is the time. When the finish is done, the shell is drilled, edged, a snare bed added, and assembled.

In comparison to a plywood shell, a stave shell uses a much smaller amount of glue. The grain runs in a vertical direction and allows the sound to travel through the wood, giving the wood a full chance to add its unique tone.

When the customer has chosen his type of wood, we carefully select the pieces to be used. We keep a small supply in stock, and have access to 120 species of wood. This picture was taken at the wood suppliers premises. [A]

The boards are prepared by straightening, run through a thicknesser and cut to staves - but the bevels are not yet ready to be cut. [B]

The wood is stored in a dry and stable place for a while and left at ease to relieve internal tension in the wood. When the rough staves are well dried and ready for action each individual stave is cut to size and beveled. [C]

You can't really see it, but the saw blade is accurately set at the desired angle! [D]

When all the staves are cut they are glued into a shell. [E]

Unlike many other builders who use a lathe, Signature Drums uses its own custom designed jigs with a router.

Outside being cut. [F]

Inside being cut. The whole process is repeated a couple of weeks later. In the meantime the wood has had a chance to dry further down and set itself again for new internal tension. [G]

This shell is ready for sanding and the finishing touches. [H]