The Fipple

• 1). Measure 6.2 cm of copper pipe using the ruler and cut it with the pipe cutter.
  
  
• 2). Sweep the rasp around the cut removing any burrs. You may also lightly sand with sandpaper.
  
  
• 3). Mark a line 3.2 cm from one end of the pipe. Measure 7.2 cm from the same end of the pipe and mark a dot. Punch a hole with the metal punch at the dot.
  
  
• 4). Drill a hole where you punched with a 1/32-inch bit. This opening is called a fipple.
  
  
• 5). Expand the round, drilled hole into a neat 6mm-long-by-7.5mm-wide rectangle using the small file.
  
  
• 6). Position a flat-ended metal bar at the 3.2mm end of the rectangular hole and hold it at about a 5-degree angle leaning into the hold. Tap the metal bar with a hammer until the edge of the hole slants 1 to 2 mm. This will create a ramp into the hole.
  
  
• 7). File a 2mm beveled edge on this ramped area of the fipple using the small file, creating a flat, clean edge. Sand the edges of the fipple smooth.
  
  

The Plug

• 1). Lathe the 5/8-inch hardwood dowel down to 9/16 inch; the dowel should snuggly fit into the copper pipe. Cut the 9/16-inch dowel to 1 inch. This piece will become the plug of the tin whistle.
  
  
• 2). Create a channel in the plug that is wider at the distant end than at the plug end. Create a flat surface first that is 5/16 inch wide at the plug end and 1/4 inch wide at the far end. Deepen the channel using the small file to 1 mm deep at the plug end and 2 mm deep at the far end. Make the sides of the channel perpendicular to the surface not sloped.
  
  
• 3). Insert the plug into the short end of the fipple tube, opposite the ramp side, aligning the channel with the fipple. Press the plug in until it lines up with the outer edge of the fipple.
  
  
• 4). Cut a 23.3cm copper tube with the pipe cutter.
  
  
• 5). Slide the open end of the fipple into the copper connector. Add the 23.3cm copper tube to the other end of the connector.
  
  
• 6). Secure the plug in place by putting three depressions, around the plug, into the fipple using the metal punch.
  
  
• 7). Cut the plug end of the fipple off at a 45-degree angle starting 2 mm below the channel on the plug. Sand the cut smooth.
  
  
• 8). Mix a two-part epoxy and apply it to the cut edge of the fipple to form a rounded mouthpiece. Dry overnight.
  
  

Tuning the Pipe

• 1). Warm the tin whistle with your breath. The goal note is a D, cut the end of the pipe if it is flat and pull it from the connector slightly if it's sharp.
  
  
• 2). Measure the following distances from the bottom of the long copper tube and mark the positions: 4.7 cm, 7.2 cm, 8.6 cm, 11.2 cm, 13.1 cm, 15.0 cm.
  
  
• 3). Create a small depression at the marks with the punch and a hammer. Drill each of the holes in the long copper tube using a different bit. Starting with the furthest hole from the fipple, make the diameters: 3/16 inch, 9/32 inch, 1/8 inch, 7/32 inch, 1/4 inch and closest to the fipple 1/4 inch again.
  
  
• 4). Clean the holes with the rat-tailed file; do not expand the hole or it will change the tune.
  
  
• 5). Sand the outer edges of the holes with fine-grit sandpaper.