The Art of Handcrafting Custom Game Calls > Handcrafting Other Items, Pens, Bowls, Forms

widgeon/teal whistle from shotgun cartridge

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adrian:
the easiest off all calls to make i think, gets a sound every time.
as before i wont insult anyone with safety with ammunition.
for the first two parts please use safety glasses etc
this works with any type of shotgun shell, i use 12 gauge as thats what i have, and i dont like to waste all that lovely brass.
 you will need two shells per whistle



the first thing is to take fired case, remove primer, i place over a vice and push out with a nail.


 then open the vice so its just wide than the base of the shell, we now have to remove the plastic part of the shell.
 i hold the plastic part with a pair of pliers,
 place the brass over a blow torch or source of heat.
when its nice and warm, not to hot.


 place the brass in the vice, tighten up slighlty and pull/twist the plastic out of the brass



in this picture you can just see the small pieces of brass triangles that are inside the head and hold the primer in.
remove any small pieces of plastic in the case.
in the background are the two plastic peices we have pulled out.
if the white part stays in the brass you have heated it to much.
take a punch ( i use a long nail with a flat head for this) push over the triangles until flat with the case.



now the tricky part that can be a real pain to get right.
 take a domed hammer

place head down in one of the cases and gently tap with another hammer until the top curls over slightly, to much and you end up with cut lips.
not enough and the next bit wont work.


place the two side by side, you can plainly see the curled outer lip.
push the two together and make sure they are straight .


holding tighly between fingers place in vice, gently tighten the vice until the curled part is flat against the other shell.

 if you have the shells nice and flat they will go together nicely.
if not, they will bulge out, in which case, bin and start again.



if they worked out, place on flat surface an LIGHTLY  tap with domed hammer.


to get this.
polish , place in lips and either blow or suck.



here are two i have done wrong to show the main faults
on the left is one that wasnt perfectly straight when placed in vice.
 the middle one has been domed to much, the two sides are touching in the middle so there will be no sound.
the right one is perfect.you can see that the one that has been intially curled fits the other perfectly. lips safe with this one

 :hunter1:


these can be turned out by the dozen, all children find them easy to blow

Shane at S.P. Custom Calls:
Thanks for that. I will try me some of those.

Shane

jcz:
Do you dome each side of the shells or just one side?

Looks easy enough, I will have to give it a try when I get some more shells to take apart. Looks like I need to visit the skeet range now!!    :duck:


Edit, I found my answer in one of your other posts. Great job on showing us your way of making all the different whistles. 

 :thanks:

Braz:
Well what the heck was the answer?  :stickman1:

jcz:
Dome each side slightly.

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