How to make a wood didgeridoo mouthpiece

How to make a wood didgeridoo mouthpiece

Step Click to Enlarge Instructions

1 Remove all of the wax from the mouthpiece of the didge. If the edges inside the mouthpiece are not smooth, then sand them at this time. You can use a drum sander for your drill to do this.

2 The next step is to make a template for making the wooden insert. I do this by sticking a large label on the mouthpiece end of the didgeridoo. I use a label from my UPS printer. (Don't tell 'em, or I won't be able to do this anymore!)

3 The next step is to very carefully cut out the template. Using an X-Acto knife, or equivalent, carefully follow the contour along the inside edge of the opening. The piece we need is the inside part that will fall inside the didge if you're not careful!

4 Now, stick the piece of label to the stock you're going to make the insert with. I use damaged didges for my material, but I'm just lucky like that. Here you see the label fastened to the eucalyptus stock that I'll cut to make the insert from.

5 The next step is to make the insert fit the opening. Because the stock I'm using is already round, I just use the beltsander to shape it. You can use a bandsaw to get the general shape if needed.

6 After you've cut it and sanded it to the shape defined by the label, it's time to test fit the mouthpiece. One trick I've learned is to slightly angle the sander so I end up with a taper, allowing the mouthpiece insert to wedge itself in. The fit should be tight, but not too tight.

7 Here, we're ready to glue in the insert and start shaping the opening.

8 Here's a side view. Use an epoxy and glue it in place. Allow it to dry thoroughly before continuing.

9 After the glue dries, round over the edges as shown here. Leave a flat area at the top as this makes it easier to get a good seal with your mouth. You can slightly round over the inside edge. Coat the surface with Envirotex or other appropriate material.

Step	Click to Enlarge	Instructions
1		Remove all of the wax from the mouthpiece of the didge. If the edges inside the mouthpiece are not smooth, then sand them at this time. You can use a drum sander for your drill to do this.
2		The next step is to make a template for making the wooden insert. I do this by sticking a large label on the mouthpiece end of the didgeridoo. I use a label from my UPS printer. (Don't tell 'em, or I won't be able to do this anymore!)
3		The next step is to very carefully cut out the template. Using an X-Acto knife, or equivalent, carefully follow the contour along the inside edge of the opening. The piece we need is the inside part that will fall inside the didge if you're not careful!
4		Now, stick the piece of label to the stock you're going to make the insert with. I use damaged didges for my material, but I'm just lucky like that. Here you see the label fastened to the eucalyptus stock that I'll cut to make the insert from.
5		The next step is to make the insert fit the opening. Because the stock I'm using is already round, I just use the beltsander to shape it. You can use a bandsaw to get the general shape if needed.
6		After you've cut it and sanded it to the shape defined by the label, it's time to test fit the mouthpiece. One trick I've learned is to slightly angle the sander so I end up with a taper, allowing the mouthpiece insert to wedge itself in. The fit should be tight, but not too tight.
7		Here, we're ready to glue in the insert and start shaping the opening.
8		Here's a side view. Use an epoxy and glue it in place. Allow it to dry thoroughly before continuing.
9		After the glue dries, round over the edges as shown here. Leave a flat area at the top as this makes it easier to get a good seal with your mouth. You can slightly round over the inside edge. Coat the surface with Envirotex or other appropriate material.