Changes

For this part, cut off the end of the pipe at the mouthpiece end.  

For this part, cut off the end of the pipe at the mouthpiece end.  

[[Image:slide_cad_24.png|500px]]

[[Image:slide_cad_25.png|500px]]

Then, create a new sketch on the end of the wire. Draw 2 circles, one the size of the wire, and the other a little smaller than the inner diameter of the pipe. Extrude this sketch to a length of ½”. Make sure that “merge result” is not checked.  

Then, create a new sketch on the end of the wire. Draw 2 circles, one the size of the wire, and the other a little smaller than the inner diameter of the pipe. Extrude this sketch to a length of ½”. Make sure that “merge result” is not checked.  

[[Image:slide_cad_25.png|500px]]

[[Image:slide_cad_26.png|500px]]

And you’re done with the cad!

And you’re done with the cad!

Welding rod  

Welding rod  

[[Image:slide_cad_26.png|500px]]

[[Image:slide_cad_27.png|500px]]

First, the notch in the pipe needs to be cut. It is important that this notch not be to large or to deep, as it will negatively effect the devices ability to make sound.  

First, the notch in the pipe needs to be cut. It is important that this notch not be to large or to deep, as it will negatively effect the devices ability to make sound.  

Start by using a hacksaw to cut a small notch vertically into the pipe. Mount the pipe in the rubber vice clamps and cut just until through the wall of the pipe.  

Start by using a hacksaw to cut a small notch vertically into the pipe. Mount the pipe in the rubber vice clamps and cut just until through the wall of the pipe.  

[[Image:slide_cad_27.png|500px]]

[[Image:slide_cad_28.png|500px]]

Next, cut in at an angle to form the notch. To start the cut, it is helpful to take a couple strokes vertically, and then cut in at an angle from that starting point.  

Next, cut in at an angle to form the notch. To start the cut, it is helpful to take a couple strokes vertically, and then cut in at an angle from that starting point.  

[[Image:slide_cad_28.png|500px]]

[[Image:slide_cad_29.png|500px]]

Cut down to the vertical notch, removing the plastic triangle. The resulting notch will be rough, so next, use a wide file to smooth out the surface. Once the surface is smooth, remove the burs left on the inside of the cut with the deburring tool. Be careful not to remove too much material, as the tip of the notch needs to be thin and sharp to produce good sound.  

Cut down to the vertical notch, removing the plastic triangle. The resulting notch will be rough, so next, use a wide file to smooth out the surface. Once the surface is smooth, remove the burs left on the inside of the cut with the deburring tool. Be careful not to remove too much material, as the tip of the notch needs to be thin and sharp to produce good sound.  

[[Image:slide_cad_30.png|500px]]

[[Image:slide_cad_30.png|500px]]

Next, we need to bend the loop on the end of the wire rod. To do this, we will use the wire bender, which has a tutorial *here*. Use the ½” center peg and clamp the wire against it as shown below.

Next, we need to bend the loop on the end of the wire rod. To do this, we will use the wire bender, which has a tutorial *here*. Use the ½” center peg and clamp the wire against it as shown below.

[[Image:slide_cad_31.png|500px]]

[[Image:slide_cad_32.png|500px]]

Once the wire is clamped in place, use the bender to bend the wire around the center peg, forming a loop.  

Once the wire is clamped in place, use the bender to bend the wire around the center peg, forming a loop.  

First, slide the cap onto the wire rod. Make sure it is pointing the right direction. Then, clamp the rod in the vice, with about ¾” protruding above it. Take the delrin cylinder, and using a mallet, gently pound it onto the wire. Stop once the wire is fully through the cylinder.  

First, slide the cap onto the wire rod. Make sure it is pointing the right direction. Then, clamp the rod in the vice, with about ¾” protruding above it. Take the delrin cylinder, and using a mallet, gently pound it onto the wire. Stop once the wire is fully through the cylinder.  

[[Image:slide_cad_32.png|500px]]

[[Image:slide_cad_33.png|500px]]

Lastly, slide the slide assembly into the pipe, and insert the wooden peg into the opposite end.  

Lastly, slide the slide assembly into the pipe, and insert the wooden peg into the opposite end.  

And you’re done!

And you’re done!