I have seen at least 2 trombones where the "horn" was made from a single piece of sheet copper. I don't have many details on the construction, but, they started by "drafting" a 2-dimensional pattern for the approximate shape of the horn, rolling it into a 3-dimensional shape, fastening the edges of the seam together (I think one used rivets and the other was soldered.) and then "hammering" the horn into final shape on an anvil. I believe they both used copper flashing from Home Depot.computergeek3 wrote:Does anyone know where to find a disc (9" diameter) of any (reasonably) malleable metal such as copper/aluminum etc. for a trombone?
The horn that was riveted had a missing rivet about 1/3 of the way up from the throat of the horn. This single hole, approximately 1/8 in in diameter was very detrimental to the sound quality and volume produced by the trombone. Plugging the hole with some chewing gun (really!) brought out the full brass sound you would expect from that type of instrument.