||This was a fun project for my son and I! Both power tools
or hand tools can be used, and the project can be completed in an evening,
perfect for kids! For the smaller whistle, start with some scrap pine,
3/4" X 3/4" X 4 1/4" or so long. Different lengths will give different
||Drill a 7/16" hole down the center 3 5/8"deep. We used
a jig to hold the stock safely. Then over to the band saw to cut the notch.
Next take a 7/16" dowel and cut it about 1 1/4" long, then flatten one
site of it with a file. This is the part that makes the sound. Stick it
in the hole flat side up to test the sound before gluing it there permanently.
||We had to resize the dowel by spinning it in the drill
press and sanding a little off so it fit the whistle snugly. We also had
to refile the flat spot a few times to get the whistle to sound ok. When
your satisfied with the sound, glue it in so the dowel is flush inside
the whistle and still sticking out the end.
||After the glue dries, you can cut the mouth piece, John
does this on the scroll saw, then sand all the faces smooth. John also
chamfered all the edges then decorated his whistle with markers!
||So it took less than an hour to make this little whistle,
and less than that to be sick of the noise! My son was very proud
of himself! This was a project that he didn't get board with and could
play with instantly! Click
here to hear his whistle!
||With simple whistle under our belts, we decided to get
into the "Quad Train Whistle". We started again at the drill press but
ran in 4 holes instead of 1. Also because of the length of the whistle
and the bit, i didn't have enough clearance on my benchtop drill press.
We started the holes with a 1/2" forstner bit.......
||...and completed the holes with the hand drill at the
vice. The holes are different depths for different tones, 4", 5", 6", and
7". We put tape on the drill bit to let us know how deep to go.
||I needed to make a "V" block to hold the whistle at 45
degrees, to make these cuts. To make the V block, set your table saw blade
at 45 degrees, and
1-1/4" high. Then take a 12" pc of 2X4 and make the first
pass, then flip the block and make the second pass. You end up with a groove
that will hold your whistle at 45 degrees.
||Start out by making the "cheek" cut with your miter gauge
set to 90. Then you can freehand the angle cuts (at right).
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