hey everyone...
I hope this post is OK... in the last couple weeks since Christmas I started making flutes again, and the response has been overwhelming. Without getting into details that would break the selling rule, let's just say it looks like I'll be able to keep doing this for a while...
But I've also gotten a few private messages here and on FB asking how I make mine... and asking my advice on how they can learn to make their own. I'm flattered, and a little surprised, because there are so many flute makers out there with much more experience than I have.
None the less... I decided I would take a bunch of pics, and show you all how I'm making flutes now. I figure why not??? For better or worse, many of you here are responsible for teaching me... hehehe...

So I don't violate the selling rules, the pieces I'm using are NOT for sale... they are a batch I'm making for myself and my step-brother, and a friend.

We start with a sick gorgeous piece of quilted maple I found right after christmas:

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This piece is nearly 27", and after looking it over, I decided to cut it into 5 blanks, 4 of them big enough for low-D's and one mid-A size:

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From here I routed the insides:

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Then one by one glued and clamped them back together.

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And routed the outsides:

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As you can see, a ceder blank has found it's way in with the rest... this is because I like to have a "Sacrifice" flute, if you will, for when I'm using the router. Ceder is very cheap and easy for me to get, so I always do my first passes with it, just in case something is off. That way if I screw up something, no big deal, I don't screw up my maple... And if nothing goes wrong, I get an extra ceder flute.

From here comes the endless spinning on the belt sander...lol...

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And eventually I get some nice round blanks....

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Now the real fun begins! I already drilled pilot holes for the SAC exit and TSH, and here I've drawn in where everything needs to be:

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Now I burn my TSH, airway and SAC exit... I do mine a little different than some makers, in that I burn most of the airway, then use a wood chisel and fine sand paper to remove the charred part and smooth it. For me this seems to work best, and makes a really clean sound.

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And this is how I end up:

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From here I add the tuning holes, if there are any:

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And check the tuning:

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OK, now the real fun part... playing holes... some makers I know do there holes one at a time, but I like to do all the pilot holes at once, so they're straight, then start burning the holes in from the bottom note up:

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Once all the holes are close to being on mark, but still a little flat, I add a quick bevel with the dremel:

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Then check again to see if the tuning is where it needs to be, and fix it if need be, and the first rough tuning is done:

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OK, from here it still needs a ton of work, but it's looking like a flute. Now I need to just sit on the floor with a big pile of fine sand paper and steel wool and polish it up really pretty. I doubt you all need a pic of me sitting on the floor...lol...
Then I'll tweak the tuning again if need be.

After that I oil it... and again recheck the tuning...
And this is the final product, the first of the finished blanks:

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And because I didn't screw up anything this time, this is the finished Ceder blank:

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So that's how I do it... mostly from learning from all of you... I hope this helps some of you just starting out....

And mostly, THANK YOU all for teaching me how to do this!!!

Very good presentation Jim. I enjoyed the heck out of it.
Awsome looking wood.
Thanks for sharing,
Don Sharp

[quote name='Just Jim' date='Jan 22 2012, 03:50 PM' post='103414']
hey everyone...
I hope this post is OK... in the last couple weeks since Christmas I started making flutes again, and the response has been overwhelming. Without getting into details that would break the selling rule, let's just say it looks like I'll be able to keep doing this for a while...
But I've also gotten a few private messages here and on FB asking how I make mine... and asking my advice on how they can learn to make their own. I'm flattered, and a little surprised, because there are so many flute makers out there with much more experience than I have.
None the less... I decided I would take a bunch of pics, and show you all how I'm making flutes now. I figure why not??? For better or worse, many of you here are responsible for teaching me... hehehe...

Very good presentation, Jim. Thank you! One question: Do you use any oil or other finish on the interior chambers?
Arthur

Jim, thank you for this! Absolutely wonderful presentation! It gives a great illustration so people can see the function of each step well enough to where they could even apply their own variation. On that note, I have what may be a stupid question... pictures 10-12. Do all flute makers have than section of nest over the block recessed creating a channel on top of the nest as well as the one in the bird? It also looks as if the top of the cutting edge is also recessed.

I ask because, as is probably apparent, I have never done this :/ I never noticed it on any diagrams I have seen.

I oil the insides and out when i finish it, yes. I know some makers that oil the interior before they glue the blank back together, but I can't stand the smell of burning oil, so I wait.

I'm not positive I understand the question. If you are refering to the airway, I only have mine in the flute bore, not in the bird. The bird is perfectly flat on the bottom.

As for the slight recess on the cutting edge, yes, good eye. The reason for this is you want the airstream to be perfectly split by the cutting edge. Because my airwway in the bore, I drop the cutting down just a hair for it to line up properly.
More or less, my airway is aprox. 1/32" deep, and the cutting edge is lowered aprox. 1/64", so it falls right dead center in the airstream.

Nice presentation - and the gorgeous wood adds to that much more to the story!

Mike

Thanks... yeah that chunk was amazing. Found it at Woodcrafter in Clearwater... you never know what they might have on any given day, but usually there is something exceptional in stock...
But this one wasn't cheap, $80.00 to be exact. I kept looking at other pieces that didn't cost as much, then coming back to this one... and in the end I bought this one instead of 3-4 cheaper, not quite as cool looking ones.
And now that I see how a couple look when they're finished, I am SO glad I did... hehehe

Answers the question perfectly

Burning the TSH , very interesting Jim . You have different size tools for different widths or do you simply work your way out ?


Side note : I see someone has been to a few Soft White Underbelly shows.

I have a few different sizes...

And props for knowing who the Great White Underbelly is....
They were my 1st concert, and one of my all time favorite bands!!!

Jim, que up some "Black Blade" and turn out some fantastic flutes!

Gladly!!!
But I have a trivia question... do you know just what the Black Blade was??? I do! hehehe

OK, I'm adding another picture... this is the flute in most all the pics, but today I polished it and gave it the first coat of tung oil:

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Amazing what a little steel wool and tung oil can do...

No, I don't?

The fantasy classic Elric of Melniboné, by Michael Moorcock. Absolutely fantastic series, and one of my all time favorites.
The Black Blade refers to his soul-stealing sword: Stormbringer. (yeah... betcha haven't heard that name before...lol)
This sword is a blessing and a curse all at once, and a central part of the series.

I've actually thought about making an "Elric" tribute flute one of these days....

They were not only great, but cleverly fun!

"Stormbringer"

Deep Purple!

Clear "Classic Rock-n-Roll" Notes,
Webb

yup... but I'm not 100% sure if the Deep Purple song refers to Elric or not.

But back to the subject, I forgot a pic.. this is my "High-Tech" method of sanding the inside of a bore: a power drill, 2 extenders and some sand paper wrapped and taped to the end... lol

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And routed the outsides:

Jim, what kind of setup do you use to route the outsides: Do you use a router table and what kind of bit? Do you have a jig wet up?

Also, the 90* file you use on the TSH: Did you heat it cherry red, bend it, then reheat and quench it (in what) to re-temper?

Great service you've done here, Jim!
Arthur

The outsides I use a roundover bit... although on these I need a slightly larger radius bit.
I do use a router table, I should have taken pics of that, sorry. I'm not sure what a jig wet-up is????

And very good call on the file... you pretty much answered your own question... I have a big,heavy old vice that works great to clamp it into red hot and get a nice fast bend before it cools down. The only thing is I don't bother re-tempering it, because I'll be constantly re-heating it when I use it. If it breaks, no big deal, I can get a pack of 10 for like $10.00 at Harbor Freight.

But I have to warn you, burning an airway like this is very delicate... you have to have the file perfectly straight, and only need to char it just a tiny bit, then chisel and then sand the charred part away... on a soft wood like ceder it's really easy to burn too deep. In fact a couple people already told me I'm nuts doing it like this... lol... and they might be right. But there's something about burning the wood vs. cutting or routing... burning just makes it sound sweeter to me... I can't explain it.

[quote name='Just Jim' date='Jan 27 2012, 03:50 PM' post='103697']
The outsides I use a roundover bit... although on these I need a slightly larger radius bit.
I do use a router table, I should have taken pics of that, sorry. I'm not sure what a jig wet-up is????

Sorry, Jim, I should have proofed it better! "Wet-up" should have read "set-up." I just wanted to know if you used a jig to guide the flute body when running it over the router or did it freehand.

Thanks again,
Arthur

Ahhhh... gotcha.
Right now I freehand it, but that's only because I have a tiny Ryobi router table, and it's not really set up to add a bunch of guides to.....

I would like a larger table eventually. I've seen a couple that have grooves and stuff cut into them to fix guides with, as well as measured grids and reference stuff drawn on them... very nice.

Wow Jim!...thanks for posting the progress pics!

I can't wait to get started, and pics are the next best thing to having someone with experience looking over my shoulder and guiding me.