Wood Magazine 29 by Larry Clayton

Author:Larry Clayton
Language: eng
Format: epub
Tags: Wood, Home and hobby woodworker
Publisher: Meredith Corporation
Published: 1989-03-25T05:00:00+00:00

Apply glue to the mating surfaces. Then, glue and clamp the pieces with the edges and end flush.

GROOVE-ROUTING SETUP

Mark lines for

stop block positions Center of bit

14%" (for second groove) 15%Mfor first groove)

Written by: Marlen Kemmet

70

WOOD MAGAZINE JUNE 1989

YOU CAN HEAR THE TRAIN A-COMIN'

^©©MWti mrami

whistle blank. Reset the stop blocks to the 14%" pair of lines (don't move the fence), turn the block around, and rout the second stopped groove.

4 Using the Routed Blank Drawing below for reference, crosscut a IVa"-long piece for the whistle bottom (A) and a %"-long piece for part B from the maple blank. Now, tilt your saw blade 45° from vertical, and miter-cut the top piece (C) to a GW finished length from the remaining maple blank.

5 For reference later when cutting the angled end of the assembled whistle, mark an X on the edge nearest the longest routed groove on both pieces.

r-*r

7%"

W

6%'

/2*

-1.V

r

®

©

/

%"

-%XlV4x16Vfe maple

-Waste -Cut1

-Cut 2

1*—Cut 3

(miter cut)

First groove

Second groove

ROUTED BLANK

16%"

HOW TO MAKE THE TOOT FOR THE TOOTER

1 Crosscut a 12" length of W dowel stock. Sand a taper on each end of the dowel identical to that shown on the Dowel Detail on the Exploded-View Drawing. (We sanded the taper on a stationary sander; if your belt sander has a flat top, set the sander upside down, and then sand the dowel.)

2 Cut two %"-long pieces from the ends of 12" section of Vz" dowel. If either piece doesn't match the Dowel Detail, repeat the process on the remaining piece of dowel.

THE END OF THE LINE-FINAL ASSEMBLY

I Spread glue on the mating edges of the whistle pieces as shown in the photo far left. Next, glue and clamp the pieces (A, B, C) together with the edges and ends flush. If you get a small bit of glue in the grooves, remove it with a cotton swab or pipe cleaner.

2 Glue the %"-long dowel pieces into the V? holes in the end of the whistle. (For the best sound, keep the dowel tapers parallel with the bottom of part A.)

3 Trim about W2" off the mouthpiece end of the whistle.

4 Using a penny, trace around its outline to mark a radius, and then mark an angled cutoff line on the end of the whistle where shown on the Radius Detail accompanying the Exploded-View Drawing. Be careful to mark the radius on the corner nearest the marked X, or you'll cut into a stopped groove when angle-cutting the end to shape. Band-saw the whistle end to shape and sand smooth.

6 Rout a W round-over on all but the mouthpiece end. Sand smooth and apply the finish. (We used Behlen's Salad Bowl Finish; a vegetable oil also would work fine.) Finally, give the whistle a blast and watch kids come running, w

Illustrations: Kim Downing; Bill Zaun Photographs: Bob Calmer

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