There comes a time in every mans life when he watches way too much "duck dynasty" and feels inspired to build his own call. I do not claim or pretend to be an expert on ducks, duck calls or duck hunting. Heck I don't even live near ducks! I built this after watching them make this on tv and looking at photos. This is how I did it and it works pretty well.
Step 1: Materials
3/4" wooden dowell - 8"
2" hard wood branch - 4"
Strip of plastic (unsure of thickness)
5/8" hole saw
1/4" drill bit ( long)
Step 2: Drilling and Shaping
Drill through the center of the dowel with the 1/4" bit and drill through the hard wood with the 5/8" hole saw. Make sure these holes are centered and straight. Cut a 2" notch in the dowel as pictured. I'd guess around 12 degrees Trim the dowel to fit in the 5/8" hard wood snugly and with little gap. A lathe would be handy here! Round the tip of the dowel as pictured and file the cut smooth. Shape and round the wood to your liking and comfort.
Step 3: The Reed
This is the most important and critical part of the call. I suggest trying a few different types of plastic. You want to cut the Reed to fit the dowel perfectly, about 1/8" from the tip and fit snugly in the slot. Crease and fold the rear of the reed to help keep it in place. Cut 45 degree notches in the front of the reed. Using the cork, cut a small piece to wedge in the upper part of the hole. Tuning; This is by far the hardest part, and I am far from an authority on the matter. Basically I just toyed and trimmed the reed until I got a sound that was duck like. Playing; Again I'm a huge novice, but I'm willing to share what I have learned. The best methods I have found is by puffing my cheeks and forcing my tongue forward. Finding what works is key!
Step 4: Finishing
Sand to 220 or so, stain the wood then clear coat. You can add a metal band or something you like. I used a part from an old hard drive.
Step 5: Final Thoughts
It sounds great but is not as loud as I like. Still toying with it though. I think a bigger hole in the dowel would help. I'll keep you posted as I develop better sounds! Any thoughts or advice is welcome. Thanks
Step 6: Reed Update
A slightly longer reed seems to produce the desired sound. About a quarter inch hang over from the dowel tip.