I thoroughly enjoyed reading through the tutorials of the FDR and the Mr. Ben method, so I figured I would post my variation as well. I don't like to measure stuff a lot, so this might be somewhat crude.....kinda like your Grandmother's recipe where she adds milk until there's "enough" and cooks while stirring until it's "right". I never make the same thing twice, so duplication is not exactly in my repertoire. I do use the same process each time, but once it comes to things that affect the sound of the call, I adjust these parameters on the fly until the call sounds "right" to me.
That's the end of my public service announcement for what's ahead. In short: This is how I do it, maybe someone can benefit from it..........
I use this method for producing both 3/4" and 5/8" bore Reelfoot Call Inserts:
1. Turn rough-shaped insert between centers making a 7/8" diameter tenon on one end
2. Mount rough-shaped insert into jig and clamp down with set screw
3. Cut lengthwise section of toneboard on bandsaw
**you will understand why later on, but this method only works if the deck height of your toneboard is above center.
4. Cut back side of wedge block using sturdy saw
**I tried using different methods of cutting this part, but this seems to be the best saw for me to get a good straight cut
5. Sand toneboard flat
**I use the table from an old joiner with double-sided tape and sandpaper (coarse grit on one end, fine on the other)
6. Sand back side of wedge block flat and touch up the back of the toneboard notch
7. Glue wedge block back to toneboard using superglue
8. Mount insert back onto lathe
**You can see in the first picture why I mentioned in step 3 that the deck height has to be higher than center.
9. Finish turning insert down to desired shape and diameter (3/4" or 5/8")
10. Mount finished insert into collet chuck
11. Drill and finish end of insert to your liking
**Don't drill deeper into the insert than the bottom of your wedge block!
12. Remove insert from collet chuck and use chisel to break wedge block free from toneboard
13. Mark desired toneboard length and mount insert back into jig
**I use a C-Clamp on the end because the set crew is just not sufficient for the next process.
14. Drill toneboard by hand. Be sure to hold back on the drill a bit as it will tend to grab if you'll let it!
This method allows you to put some angle on the tone channel as well if you are good enough with the drill!
15. Finish sanding the toneboard using the fine grit sandpaper and cut the desired length of your wedge.
16. Insert reed and tune it!
Let me know if anything needs clarified!
Bear