The Cajun accordion, also known as the two-row diatonic accordion in some circles, has a unique design that sets it apart from other types of accordions. It typically features two rows of buttons on the right-hand side, which are tuned to play in a specific set of keys, usually C and G. The simplicity of its button layout makes it accessible for beginners, while its rich, full-bodied sound makes it a staple in Cajun music ensembles.
Building a Cajun accordion requires a combination of woodworking skills, knowledge of musical instrument construction, and patience. While it may seem like a daunting task at first, with the right guidance and a commitment to the process, you can create an instrument that not only looks beautiful but also produces the authentic Cajun sound. This guide will break down the complex process into manageable steps, providing you with the information and resources you need to embark on this exciting musical journey.
Tools and Materials Required
Tools
Saw: A fine-toothed handsaw or a table saw is essential for cutting the various wooden parts of the accordion. A handsaw gives you more control for intricate cuts, while a table saw can be more efficient for larger, straight-cut pieces.
Chisel Set: Chisels are used for shaping and carving the wood, especially when creating the slots for the reeds and the channels for the air to flow.
Router: A router is useful for creating precise grooves and channels in the wood. It can be used to make the tracks for the bellows and the mounting areas for the buttons.
Screwdriver Set: You will need a variety of screwdrivers, both flat-head and Phillips-head, for assembling the different parts of the accordion.
Clamps: Clamps are crucial for holding the wood pieces together while glue is drying. They come in different sizes, and having a range of them will be beneficial for various stages of the construction.
Files and Sandpaper: Files are used to smooth and shape the edges of the wood, while sandpaper in different grits (from coarse to fine) is essential for achieving a smooth finish on all surfaces.
Drill and Drill Bits: A drill with a set of drill bits is needed for making holes for screws, pins, and other hardware.
Materials
Wood: High-quality hardwoods such as maple, oak, or walnut are commonly used for the body of the Cajun accordion. These woods provide strength, durability, and a good resonance for the sound. You will need enough wood to create the bellows frame, the keyboard and button-side panels, and the reed-block housing.
Reeds: The reeds are the heart of the accordion, as they produce the sound when air passes through them. Cajun accordions typically use brass reeds. You can purchase pre – made reeds from musical instrument supply stores or, for more advanced builders, make your own reeds from brass sheets.
Bellows Material: The bellows are usually made from a combination of leather and paper or a specialized bellows material. Leather provides flexibility and airtightness, while the paper or other material gives the bellows structure. You will need enough material to create the bellows that can expand and contract smoothly to produce the air flow for the reeds.
Buttons and Key Mechanisms: For the button-side of the accordion, you will need a set of buttons. These can be made from various materials such as wood, plastic, or metal. You will also need the necessary springs and rods to create the key mechanisms that connect the buttons to the reed-actuating system.
Glue and Fasteners: High-quality wood glue is required for assembling the wooden parts of the accordion. You will also need screws, nails, and pins to secure the different components together.
Building the Body of the Accordion
Cutting the Wood Pieces
First, measure and mark the dimensions of the various parts of the accordion body on the hardwood boards. The body typically consists of two main sides (the keyboard side and the button side), a back panel, and a front panel. The bellows frame also needs to be cut to the appropriate size. Use a saw to carefully cut out these pieces, ensuring that the edges are straight and smooth.
For example, the keyboard side panel may be around 10 – 12 inches in length, 6-8 inches in width, and about -.5 inches thick. The button side panel will have similar dimensions but may have different cutouts for the buttons.
After cutting, use a file and sandpaper to smooth the edges and remove any rough spots. This will not only make the parts look better but also ensure a proper fit when assembling.
Shaping and Assembling the Body
Once the pieces are cut, use a chisel and router to create the necessary grooves, channels, and cutouts. On the keyboard side, you will need to create channels for the key mechanisms and a flat surface for mounting the keys. On the button side, cutouts for the buttons and channels for the button-actuation rods need to be made.
For the bellows frame, create grooves around the edges where the bellows material will be attached. Use clamps to hold the pieces together while applying wood glue at the joints. Make sure the joints are tight and properly aligned. Let the glue dry completely according to the manufacturer’s instructions.
After the glue has dried, you can reinforce the joints with screws or nails, especially in areas that will experience more stress during playing.
Creating the Reed-Block
Designing the Reed-Block
The reed-block is where the reeds are mounted. It is designed to direct the air flow from the bellows to the reeds in a precise manner. Sketch out the design of the reed-block on a piece of wood, taking into account the number and arrangement of the reeds.
A typical Cajun accordion reed – block may have two rows of reeds, with each row corresponding to a different set of notes (such as C and G). The reed-block should be sized to fit snugly inside the body of the accordion, with proper alignment to the button-actuation mechanisms.
Cutting and Shaping the Reed-Block
Using a saw, cut the wood for the reed-block to the desired size. Then, use a chisel and router to create slots for the reeds. The slots should be carefully sized so that the reeds fit tightly but can still vibrate freely. The depth and width of the slots are crucial for the proper functioning of the reeds.
After creating the slots, smooth the surfaces of the reed-block with sandpaper to ensure a clean and even finish. This will help with the air-tightness of the reed-block and prevent any air leaks that could affect the sound quality.
Mounting the Reeds
If you are using pre-made reeds, carefully insert them into the slots in the reed-block. Make sure each reed is seated properly and is aligned correctly. If you are making your own reeds from brass sheets, first cut the brass to the appropriate size and shape for each reed.
Use a file to shape the tips of the reeds and adjust their thickness to achieve the desired pitch. Then, solder or use a specialized reed-mounting adhesive to attach the reeds firmly to the reed-block. Once all the reeds are mounted, test them individually by blowing air over them to ensure they produce a clear sound.
Constructing the Bellows
Preparing the Bellows Material
Cut the leather and paper or specialized bellows material into the appropriate strips. The leather strips will form the air- tight seals, while the paper or other material will provide the structure for the bellows to expand and contract.
The width and length of the strips will depend on the size of the accordion bellows. Generally, the strips should be long enough to wrap around the bellows frame with some overlap for attachment.
Assembling the Bellows
Start by attaching one end of the leather strip to the bellows frame using glue or small tacks. Then, layer the paper or other material strip on top of the leather strip, followed by another layer of leather. Continue this process, alternating between leather and paper, until the desired number of folds for the bellows is achieved.
Use clamps to hold the layers together while the glue dries. Make sure the folds are evenly spaced and that the bellows material is tightly adhered to the frame. Once the glue is dry, test the flexibility of the bellows by gently expanding and contracting it. There should be no air leaks, and the bellows should move smoothly.
Conclusion
Building a Cajun accordion is a challenging but incredibly rewarding project. By following the steps outlined in this guide, you can create an instrument that not only pays homage to the rich Cajun musical tradition but also reflects your own craftsmanship and dedication. Remember, the process may take time, and there may be some trial and error along the way, but the end result-a beautiful, hand – made Cajun accordion that produces the unique sounds of Louisiana-will be well worth the effort. Whether you plan to use your creation for personal enjoyment, to play in local Cajun music events, or simply as a display piece, your hand-built Cajun accordion will be a testament to your love for music and the art of instrument making.
