TONEBOARD/INSERT .........

[Waccamaw Calls]

Parker this is how I make toneboards
I had to make a duck so I thought I'd shoot some pics, I have not forgot your owl toneboard, it's next !!

1. cut a piece of 5/8 delrin to 4" and chuck it in the collet (Al supplied the delrin some time back)
index the drill bit to 3 1/2"    ***** word here!! ONCE YOU BEGIN TO DRILL, DRILL COMPLETE CHANNEL AND REMOVE THE BIT !! *****




2. Use a reamer to open the exhaust (for the owl toneboard do not use reamer... Depending on style Open water or Flooded timber set the depth)



3. Set in jig to mark "O" ring (I use an "O" ring on the inboard end of the insert since this allows the insert to be changed [competition calls], it may however be glued in place)



4. With "O" ring groove cut and taper turned, time to cut the toneboard at the scroll saw



5. I have one side of my jig covered with tape (it helps me to see the blade)
    When the cut is made there hardly ever is a need to "touch up". Delrin cuts clean (for me any way!!)



6. The finished toneboard has the cork and reed in place and is inserted into the exhaust.



7. Once assembled it turns into one nice call ................ A Pair of Aces Swamp Runner




hope this helps,
Bill

[Cigarman]

Bill, Where did you get your jig and reamer? 

[Waccamaw Calls]

A good friend made the jig for me  serveral years ago
the one in the picture is one of five that I use
the reamer was ordered from HUT

[Cigarman]

Thanks.  Do you know any one that makes the jigs or sell them at a reasonable price.  The only one I have found on the internet was a little pricy   :(  or is $80 the norm.

[Waccamaw Calls]

$80 is cheap for a jig, but please be sure it has not been screwed with!!
There are some good jig makers out there, but most of the "on the shelf" jigs are called Public.
To get a jig made that suits your calls, you should make a master board with the rise/fall and radius that you design.
Then take that to a tool and die maker and have a jig made from hardened steel.
Mine are cut with a laser, thank goodness I have some good friends.

[VECtor Calls]

 ;D  That's some serious work!  I'm patiently waiting on how you turn that duck call idea into an owl hooter.   ;D   :D

Thanks for sharing.  That's great information.

Parker

[John_NY]

Do you sell these Calls? What kind of customer is buying it if you do

Looks like hammer time. If I was a moderator you'd be gone by now.

John