Castanets

[NMScroller]

My woodworking passion was sparked when I couldn't find exactly what I wanted. So, I bought a chop saw and circular saw and went nuts on a simple fridge stand for my office.

This project is similar. I am dissatisfied with the castanets my students are using for one of our songs so I'm working on this.

I believe the model (top left, and borrowed) is rose wood. The first generation copy is top right...in which I learned that stack cutting 1" grenadillo is next to impossible regardless the size 12 blade. Also, the bowl cut is a challenge. If only I had a band saw and a lathe....hmmm....

Bottom left is a working piece and bottom right is the other half of the pair. the bowl cut became super easy with a huge "dish" router bit from MLCS and you cut the bowl first.

The whole process is:
1) Bowl cut before you cut the blank (from the same board)
2) Chop out the blanks and trace the pattern around the bowl
3) Sand the bottom flat while take some of the bowl down a bit
4) Face match bowl to bowl and sand two halves flush with each other so they meet exactly
5) Shape the outside
6) Buff with 220 grit sanding mop then 400
7) Cut mounting holes and spring grooves.

Any thoughts on how to make it a little easier? Such a complex and specific shape requires a few steps for accuracy.

[CanadianScroller]

Very cool project.
I really like the router bit solution.
You said stack cutting is a pain with the type of wood you were using. Have you tried other woods.
I know padauk makes a very crisp metalic sound when struck together.
Do you have a thickness sander flatten the wood surfaces?
Do you have access to a jointer?
You could also cut the shapes with a template and a pilot bit on the router.
That would be quicker on the thicker wood.
Ho[e others come up with some good ideas to help, I really like this project