The materials you will need include:
- Access to a laser cutter (I will be using a CO2 laser)
- 0.115" plywood sheet
- Adhesive (I will be using carpenter's glue, although super glue may work)
- Access to a modeling software such as AutoCAD, Inventor, or any other .DXF compatible sketching software (Optional)
Step 1: Sketching the Parts
If you do draw your own version, keep in mind that the wood will be 0.115" thick, so you will need to make the sockets 0.115" thick to make sure that the pieces fit together nicely.
NOTE: You can engrave a design on the sides or top of the sketch by placing the graphic on the face of the sketch in a drawing program. If you do this, place the graphic on each side piece so that when building the whistle, the graphic always points outwards.
Step 2: Cutting the Pieces
After cutting the pieces in the laser, you will need to sand down the top piece so that a slanted edge is created at the notch in the front.
Step 3: Assembling the Pieces
When assembling the whistle, it's necessary to make sure that the sanded edge of the top piece is facing upwards. Also, it is important to note that the two mouthpiece parts fit together so that the partially-printed areas fit together in the middle. This will be where you blow air through.
Make sure the glue does not block the airflow through the mouthpiece, and that the whistle is as airtight as possible. This will ensure that the air moves throughout the whistle without escaping, which could prevent a sound from being heard.
Apply the adhesive (in this case, I will be using carpenter's glue) to the joints, and hold the pieces in place using rubber bands or clamps.