Pipe making 2

It was important to stick the pipes together very squarly but this was not much of a problem with a good jig. It was important to make sure that each edge was sealed with planty of glue so that it was air tight. When all the square pipes had been stuck together then the mouth pieces and lids to the pipes could be put in. These also needed to be square and fit in exactly. I made the mouth pieces all the same angle but using a router across all the mouth pieces before cutting them out. When all the glue was dry I sanded them down. It is important to sand the front of the whistle very flat so that all the whistels have the same gap created by the front cover. Too much of a gap caused by over sanding would not make a good sound. And not enough of a gap would make it hard of the air to escape from the top of the whistle.

The front covers were made buy sticking all the covers onto some mdf then putting the bottom front covers through the circular saw at the angle. The top front covers where given a round edge by the router.

The most important angle is the one of the mouth piece after it was routered it then had the tip sanded to a different angle. Just the top 1mm needs to have this slight angel. I did this all in one go with the mouth pieces stuck to a board.