Brian,
You’ve given me the idea to make one myself!
I’ll probably start with a good hardwood like maple or rosewood. Hollowing out a chunk of wood is difficult without the right tools, like a mill or dedicated mortiser. Therefore, I would be likely to make it from glued-up pieces to make the sound chamber versus trying to hollow-out a sound chamber.
The top (striking surface) has to be thin enough to give a good, hollow sound, but not so thin as to break from being struck. I’m thinking about 1/8 inch? I think the rest of the block’s mass just serves to give the block some resonance.
What do you think?
Josh
ps. I recently made a castanet “machine” based on a Youtube video. I made my own castanets on the lathe. They sound okay, but not as good as legit castanets, and I think it’s because there was not enough mass to them to make a good, loud sound.