Flute building is an ever-changing process; if done right, methods are always gradually changing. Here is the method and order generally followed at the present time...
High-grit sand paper and steel wool are used to smooth imperfections and remove product markings on the PVC or bamboo.
Occasionally, higher grit sandpaper is used to create wood texture when desired.
The mouthpiece is always built before any other part of the flute. Two cuts are made at one end of the pipe; one of them is made to make room for a small wooden insert to be attached a little later. The other cut forms the shape of the mouthpiece at the very end of the flute.
Before any essential wood pieces are attached, a small groove in the mouthpiece is chiseled out. This becomes the shaft through which air is blown into the flute.
Perhaps the most essential part of this type of flute is what I call the wedge. It is a small, very thin piece of wood that is glued into the flute as part of the mouthpiece. The wedge is sharpened on one side, so as to nearly 'split' air as it passes into the flute. It is inserted into the section that has, at this point, been cut out of the flute.
Two small pieces of wood are glued to the top of the wedge on either side, which act to control and concentrate air as is is blown in.
The wedge must be placed in a very presice place; being placed 1/16-inch above or below the base of the airflow will cause the flute to have cheap or no sound.
Completing the Mouthpiece
Once the glue has dried from the previous step, a 1-2 inch dowel is plugged into the end of the mouthpiece. It must be sanded down on one side, and the sanded side lined up with the groove that has been cut in the flute. This finishes the 'schute' into which air will be directly blown.
The dowel is then cut to fit the shape of the PVC or bamboo at the end of the flute, completing the general shape of the mouthpiece.
Holes are drilled on one side of the flute, and placed where fingers can comfortably cover them. A few factors are put into what size each hole turns out to be. This entirely depends on the scale that the musician wants to play. Most of the flutes made by this company are tuned to major chords, but they can be made in nearly any desired scale; minor, wholetone, arabian-style, etc. The scale one desires determines the sizes of these holes and sometimes the distance between them.
All sections are then sanded smooth, holes are cleaned out, and general designs in the wood pieces or pipe are carved.
Each flute is painted with a main background color, and customized designs or pictures are hand-painted on.
3-4 coats of acrylic fixative are applied, and the flute is stored on a protective wooden structure, and then covered to await its musician.
Jake, the Flutesmith of Willowrise
Shop Jake's Hand-Made Flutes Now!
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