Gathering parts & tools
It is assumed at this point that you have gathered all the materials from the parts list. You will also need a few tools, namely --
- #2 Philips Screwdriver
- Bandsaw (wood)
- Pen or scribe for tracing template
- Ruler or measuring device
- Hand drill or drill press

Step 2: Cutting out the bracket
The main structural component of the flutophone is the bracket that houses the servos. The servos themselves are an integral part of the structure as they regulate the spacing between the bracket sides.

You'll need to either print out a template and trace it onto your sidewall material, or draw it by hand with a pen and ruler. It will be faster, easier, and more accurate to simply trace the pattern from a printed template.

The bracket side walls are made from hardboard, plastic, or some other lightweight rigid material. The servos get mounted to this indirectly, so it doesn't need too much structural rigidity on its own.

Once you have the templates traced, carefully cut out each side (2 pieces) with the bandsaw. Try to make them as close to a matched pair as possible. If you can't do it very accurately with the bandsaw, cut a little large and fix up with a hand or electric sander/grinder.

You will also want to drill holes (>1/4"OD) in each of the side walls for the servo wires to pass through. You can either drill all 7 holes in each wall or only the holes needed -- four in the lower steps of one side and three in the upper steps of the other side.

Making the side rails
The 1/2" wooden sidewalls are what gives the bracket assembly its strength. These are the stair-step formations that the servos get mounted to.

Follow the same procedure as above, tracing and cutting out each piece (4 total). You'll end up with two top pieces and two bottom pieces.

"Dry Fit" the servos
Position the side rails and servos together and do a dry fit visual inspection. To line everything up you'll need to pass the servo wires through the appropriate holes and pinch the bracket sides together.

If everything looks good, make note of where each piece is (it might not fit together as well if you mix up the parts) and start drilling a few mounting holes.

If you drilled the wire passage holes assymetrically, make sure that the thee upper holes are on the right side of the bracket with "C" opening facing you, and the four lower holes are on the left side of the bracket with the "C" opening facing you.

Attaching the servos
This step needs to come before attaching the side walls and side rails since you can't access the servo mounts after that stage.

You may need to mark down through the servo mounting holes (4 each) and predrill to avoid splitting out the wood. Each servo will be attached to two side rails. Four servos will be attached to the two lower side rails, and three servos will be attached to the remaining two upper side rails.

Use the servo mounting screws to snugly attach each servo to it's pair of rails.

Assembling the bracket
Remember, each side rail has two holes at opposite ends of each 'step' so when mounting the rails to the bracket walls, drill the mounting holes in the middle of each step (see picture).

Use small wood screws or hex head screws (flush mounted) to attach the side rails to the bracket walls.