How to make your own whistle. With this instructable we can free America from it's dependence on foreign made whistles.
Step 1: Get Wood
Got wood? Great!
I used a "pen blank", that's a 3/4 x 3/4 x 5 inch piece of wood. Woodcraft sells a five pound grab bag for $13, so I have plenty of wood.
In addition to the wood, you'll need a 5/16th drill bit and a 5/16th hardwood dowel.
You can start by drilling a 5/16ths hole down the center of your piece of wood. How deep? Less deep than the wood, or if you need exact numbers, the hole should be x-1 inches deep, where x is the length of your piece of wood. Use a drill press and a vice, if you choose to freehand it, please clamp the wood in something, you don't want splinters do you?
Step 2: The Window and Lip
Did you know the parts of a whistle have names? I didn't, but I learned some. So in this step, we'll be making the window and the lip, one is the consequence of the other, so let's just make the window.
Start by using a razor saw to make a transverse cut approx one inch from the drilled end. Cut down as squarely as possible. Stop when the blade of the saw extends approx 1/8th of an inch into the hole.
Now using a chisel (mine are muy dull), cut towards the slot you just cut, making about a thirty degree incline, make the cut as smooth as possible. Stop when the you have sliced into the bore hole about an 1/8th of an inch.
Step 3: Fipple and Windway
If you blow into your whistle now, nothing happens, we need to create a windway that guides the air over the lip, this is called a fipple. The fipple is made from a piece of 5/16th hardwood dowel about one and a half inches long. Using your chisel, slice a flat onto the top of the fipple, now slide it into the hole with the windway on the same side as the window and lip, insert the fipple until the interior end is just inline with the window.
Now what you've been waiting for, blow your whistle, sound okay? Great, if not, back out the fipple, or push it in a little farther, still bad? make another fipple, try two or three, see which sounds best. A pair of vise grips makes adjustment easy.
Once you are happy, change nothing! Use some thin super glue and wick it in around the fipple, don't get it in the wind way.
Step 4: Make It Pretty
If you want, you can stop at the previous step, just trim down the fipple flush and you have an ugly whistle. But I chose to try turning my whistle.
A confession, I didn't use my drill press lathe, I had such a good time using it, that after careful accounting and discussions with the wife, I went to Woodcraft and bought a Jet mini lathe. I just have to give up beer for a year.
So without further ado
I chucked the whistle into my lathe, using a scrap block to prevent the tailstock from pushing the fipple out of place.
Step 5: Shaping
Next I roughed it to round and shaped the mouth piece
Step 6: Finally
I rounded the end, and added a groove for a lanyard.
A little sanding and a buffed on coat of lacquer and it's ready to slip into my pocket.
Hope you enjoyed it!!!