Preparations for the festival begin about a week before opening night. Workers use large saws to cut giant blocks of ice from frozen lakes. Each block weighs about 3,500 pounds!
Carving each instrument can take up to 12 hours, says Bill Covitz. He’s an ice carver from Connecticut who helps with the festival almost every year. To start making an instrument, Covitz cuts out a rough shape with a chain saw. He uses smaller tools, like chisels, to shape finer details. Carvers work outside, where the air is usually about 19°F in the winter. That’s well below water’s freezing point of 32°F.
To hollow out a horn, Covitz slices a piece of ice down the middle. Then he carves a groove in each half for the musician to blow through. Finally, he puts the halves together and sprays them with water. The water quickly freezes solid, sticking the two halves in place.