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Every one of Toussaint's pans are individual works of art, all slightly different, all hand made from scratch.
All of the pans start off as either 45 gallon or oversize oil-drums. Toussaint then uses a large hammer to drop the flat end of the drum into a deep dish shape. Templates are then used to mark out the different notes, the shapes and sizes being critical to obtain a perfect note.
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| Carlo Norville sinking a galvanised bass | |
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The depth the drum is sunk to depends on the instrument required. Basses are relatively shallow whilst the tenor pan is deeply dished giving a shrill sound. Great care has to be taken to ensure the thin steel isn't split during this sinking process.
Next the edges of the notes are scored using a punch to define the border between the vibrating note and the non-vibrating metal surrounding it.
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