I start out with a 4 1/4" blank, normally the exhaust on my calls is 1 3/4 long and I will use 4.5" blank but I am trying a 1 1/2" exhaust this time.
I mount it in-between centers, round it, and mark where my exhaust will be.
I used to grab the blank with my chuck, turn the 5/8 tennon and put it in my collet chuck. Actually, I still do this for acrylic, but for wood I don't.
After that I turn the tennon, cut the O-ring groove and turn the exhaust. I also sand it up to 600 while still mounted between centers. (It is not sanded in this picture)
Once I finish sanding I take the drive center out and replace it with my Collet Chuck. I put the insert into the collet chuck, True up the end, drill the whole and step drill it to the size I use. I also sand the end since I was not able to sand it in-between centers.
I drilled this one just a little off-center, so I mount the drill chuck in the headstock with the bit still in it. I put the insert back on the bit and turned the lathe on. Slowly put a pencil up to it until it hits the highest point.
Once you take it out of the chuck, put it into your jig. Put the pencil mark up in your jig. I actually messed this one up a little, but not to bad so it will go on my lanyard. The sound is great. My calls have been lacking a top end (that I like) and this one has it. Sounds absolutely amazing. I saw a post on here and I was having the same problem so I shortened the exhaust by 1/4 and it worked.
Hope this helps someone.
