Make Your Own Whistle

Use your Proxxon tools to make this timeless childhood favorite toy—the whistle. 

Supplies and Equipment

• 4" length ¾" dowel
• 2" length 3/8" dowel
• Liquid wood adhesive
• Proxxon MICRO Bandsaw MBS/E
• Proxxon MICRO Woodturning Lathe DB 250
• Proxxon Disc Sander TSG 250/E
• Proxxon Delta Sander OZI/E
• Proxxon Precision Vice FMZ

Instructions

1. Measure and mark the lengths of the dowels.
   
   
   
2. Cut dowels on bandsaw.
   
   
   
3. Measure and mark the ¾" dowel for the length of the whistle hole.
   
   
   
4. Use a center finder to mark the center of the dowel.
   
   
   
5. Attach the drill chuck to the tailstock of the lathe, and insert a 13/64" bit. Mount the dowel in the chuck. Center the drill bit on the marked center of the dowel and drill a 1½" hole. Drill slowly, and frequently pull the drill bit out of the hole to empty accumulated sawdust.
   
   
   
6. Cut the whistle notch. Measure ½" from the top of the hole end. Make a cut on the bandsaw approximately half way through the dowel. Next, cut the diagonal notch line.
   
   
   
7. Smooth the edges on the disc sander.
   
   
   
8. Using the Delta sander mounted in the precision vice, sand down one side of the 3/8" dowel a bit less that half way and about 1½" long.
   
   
   
9. Insert this plug into the drilled hole with the flat side facing the open notch. Now, experiment. Rotate the plug bit by bit, and move it in and out of the hole until you get a good sound. Mark the cut line on the excess plug.
   
   
   
10. Glue the plug in place with liquid wood adhesive. When the glue is dry, cut off the excess plug and sand the end smooth.
    
    
    

You can also use these same steps to make whistles out of square pegs :)

Carole