I had some guys at work ask me how to make an Arkansas style duck call insert. So, I read up on a couple of methods of how to do it. Here is method two.
I started with a 1" diameter rod that was 4" long, and I mounted it in my 4 jaw chuck.
The next step is to drill the exhaust hole and tone channel. I use a drill stop on the drill bit to drill the exact depth that I need. I always double check that the drill stop is at the right depth.
Drill the blank to the proper depth.
One of the downsides to drilling the insert after it is turned to shape is the risk of drilling the tone channel off center. But this method will eliminate that risk.
Remove the 4 jaw chuck and install the collet chuck. The hole that we drilled in the blank was 1/4". Install a short piece of 1/4" diameter steel stock into the collet chuck. This will be used as a blind mandrel.
Install the drilled blank onto the blind mandrel.
Turn the insert to the desired shape, and final sand when done.
Remove the insert from the blind mandrel, and place it in the toneboard jig. Knowing how deep you drilled the insert, measure from the exhaust end of the insert to your reference point on the jig. Secure the insert in the jig with the set screw.
Take the insert to the band saw, and cut off the excess part above the toneboard jig. And cut out the cork notch. I don't cut right against the jig with the band saw blade because it dulls the band saw blade quickly.
I then take the toneboard still installed in the jig to the belt sander, and sand down to the profile of the jig.
Remove the insert from the jig, and it is ready for a reed, cork and tuning.
And feedback is appreciated.
Thanks,
Brian
