This instructable is more of a guide and an inspirational on how to run small scale home production on PVC pipe instruments and just about anything in general, hence the more of a guide.
So I won't be going into specifics about sizes, dimensions, and such this is already covered
in my shackuhachi instructable. http://www.instructables.com/id/How-to-make-a-Shakuhachi/
DO NOT CUT OLD PVC ON ANY KIND OF CIRCULAR SAW, IT WILL SHATTER AND HURT YOU. THE OLDER PVC GETS THE MORE BRITTLE IT GETS AND IS PRONE TO SHATTERING. (don't ask me how I know)
Things to keep in mind about producing.
What ever you can do to reduce the time you spend doing something is better.
Such as making jigs, or if you can automate a procedure. If you can automate you can set it and go on to do other things that can't be automated, effectively doubling your man power.
Try to reduce cost. You can do this by; reducing the time on a particular procedure by making jigs and automating. IE producing more using the same amount of time. Using less material or making more efficient use of the material you have IE generating less waste.
Checking your production system:
Run one unit all the way through first. You want to do this to ensure you have your process and production system down. You don't want to get to the end of your first run and find that they are all ruined because you missed something.
Do one thing at a time a number of times:
Do each procedure of the process one at a time, IE cut fipple's and do nothing else until you are done with all the pipes. Not even removing flashing or anything of the sort. If you miss one unit and have gone on to the next step in production, leave it! don't go back and do it, it's wasting time. Leave it for the next run.
You are your own quality control.
You should be inspecting at the beginning middle and end of every step of the process.
The purpose of quality control in not just to ensure good workmanship but adjust and or improve the process if quality is not being met.
PLAN PLAN PLAN!
Even though it's the last section in this intro it's the first and last thing to do.
Make sure you have a plan before going into action. Plan out your raw materials, cost, time for a production run, cost per unit. This includes raw materials, man power, overhead, tool cost, electricity...ect. Keep in mind even though you may already have drill press, drill bits, sandpaper ect.. they will need maintenance, sharpening, and replacing. You may not see it
on the front end but you will see it on the back end sooner or later. So factor that in.
Once your done with your first production run take a good look at your process and look for improvements.
How can you work more efficiently but not necessarily faster, sometimes trying to hurry will cause waste, poor workmanship or worse injury. Work smarter not harder.
Look to see where can you eliminate waste, recycle and reuse. It's not just good for the environment it's good for your wallet! If you make efficient uses of your resources you will conserve them and not have to purchase as much for the next run, in turn saving you money.
And lastly what improvements can you make to the product. Look for ways to make your product(s) better or more attractive to potential customers. Set your self apart from the compition.
Step 1: Raw materials
I started with 3 10ft. lengths of 1" SCH 40 PVC pipe
At 21 1/2" this will yield 15 flutes
measuring and marking devices
Tools I used
radial arm saw
A side note on tools and materials;
Don't be afraid to dumpster dive, get what you can for free.
Check the free section in Craig's list. For example, some one is giving away a beat up used up desk. Look to see if you can salvage the wood from it and re-purpose it. Like cutting
it up for knife handles.
another example the place where I was just laid off from had a large band saw. When the saw became dull the saw blade was tossed in the trash. I asked If I could have it and now it
can be re-purposed to become knifes! The saw blade will make great knifes, it's high carbon steel and has already been heat treated so all I would need to do is shape it and sharpen it.
Also don't be afraid to modify old and discarded power tools to do your biding. It's all about working smarter not harder.
Always keep on the look out to see what you can use and re-purpose.