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Is there a cork in the end of the flute in addition to the PVC end cap? If there isn't then that is most likely creating the problem. The distance from the end of the cork to the embouchure is really important but you can't get it anywhere near close enough with just an end cap like you're using. I've seen people make flutes with just a PVC end cap and no cork, but I could never get one to work.
I've only made flutes that use dimensions calculated with flutomat and it's always been pretty accurate for me.You might want to recheck the PVC diameter and other dimensions then try recalculating. Otherwise you could just use trial and error: Make a couple flutes and for each one move the holes in the direction needed to get the diameters to something you're comfortable with while playing still in tune.
I used a hand-held drill and a standard twist drill bit set.
I used a hand-held drill and a standard twist drill bit set. A drill press is probably unnecessary.
There's no clutch on this one which works fine for cruising but you have to stop the motor completely whenever you stop the bike.
I don't think I understand what you mean by too powerful. The problem with push mower engines is most of them will only work with the shaft oriented vertically.
A carbon fibre violin i made from scratch
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