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Making the Calls

My calls are not sent out to be CNC Machined. They are made by me, with my hands, using a manual lathe and other tools.

1.The Material is ordered in 8 foot lengths.

2. The Material is rough cut to the finish length.

3. The length is finished to size.

4. All holes are drilled, and the hole size depends on which call I'm working on.

5. Once I have my holes finished, I put the part on a mandrel. I will then turn the outside shape of the call using several different cutting tools.

6. The calls are now finished, inside and out, and are ready to be vapor blasted. I sand in the lathe then use sand or glass beads to rough up the surface of the calls (inside and out). This Process helps the sound of the call or I wouldn't even rough blast. I could keep the call polished like everyone else, but it doesn't sound as good.

7. The Barrels are then sent out for laser etching.

8. All the pieces are finished now and it is time to sit down and tune the calls. This is my favorite Part to do and is why I make calls. Each call is tuned at least 2 times and some may get it a 3rd time.

Note:

The Duck keg is rough made by a supplier of mine. It is a softer material than acrylic, but it is the material that I chose it to be. It took several times to get the "Rough Kegs" correct. The Keg is my design and is only made for Wingtipsdown. I then take the rough Kegs and machine o-ring grooves in them using the lathe. I then work on each keg using file and sandpaper to get the sound I'm looking for. Every Keg has to have the toneboard finished this way.

Manual lathe used for all drilling and turning of the calls.

The Vapor Blaster used to create the rough surface (inside and out) on the calls.

The tools I use for making the calls.

I wanted you to see how easy it would be to polish the calls. This call was machined outside and inside. Look how clear it is. I do not like the sound created by a polished call. I have made my call both ways and it sounds better with the roughness applied. I will go the extra step, to blast them inside and out.