| This is the most frequently asked question whenever any flute maker does a show.
Unfortunately, it is also the most frequently unanswered question by most flute makers.
Perhaps it is an inappropriate question to ask, but people still ask it. People also want
to know if my flutes are handmade. Some flute makers claim to make their flutes "by
hand". Perhaps they do, but I do not. I use power tools just like any modern man who
makes his living making musical instruments. I use a few simple power tools including a
small band saw, a small router, a bench top jointer, a palm sander, a drill, and a Dremel
tool. I do not use a lathe. I tune each flute by hand. That is, I form the square sound hole entirely by hand with small files and sandpaper. This is where the sound is produced and I take most of my time working this part of the flute. The finger holes are bored with a small high speed stone bit and tuned one at a time until all five holes are as close to perfect as possible for each flute. The rest of the flute is constructed with power tools. Finally, I do a finished sanding by hand and apply shellac by hand with a soft cloth, known as a French finish. Let the finish dry for a few hours and do it again by hand, this time using 0000 steel wool and more shellac. This could be done as many as 15 times for a high gloss natural shellac finish. I only do it three or four times, depending on the wood. Some flute makers use a single coat of polyurethane, but I prefer the natural non-toxic qualities of shellac. So, how long does it take? Have you ever watched Norm Abrahms on his PBS show, "New Yankee Workshop"? That guy can build an entire roll top desk in a half hour! OK, so the video is edited a bit, but still, the idea is that with power tools, wood can be worked very quickly. Here is what I do: I start with a piece of western red cedar, 2" x 2" x 8'. I cut that into four pieces - each 2' long. I do that by hand with a very sharp Japanese back cut saw. (That takes 2 minutes.) Taking one of those pieces, I mark it right down the center of the 2' length, walk over to the band saw and cut it in half along the line (3 minutes). Then, I set up the router with the proper bit (3 minutes), mark the pieces and rout the two halves. (This is done in steps, but doesn't take any longer than 10 minutes. This is a high speed tool and I use very sharp carbide bits). Next, I run those pieces over the jointer to ensure a perfect glue seam (less than l minute), walk over to the glue station (15 seconds) and glue and clamp the two pieces together (10 minutes) and wait for the glue to dry. (l whole day, but I don't count that as labor. Watching glue dry is not hard work.) We are into the process for 30 minutes so far. The next day, remove the clamps and walk over to the jointer and run the piece (now hollow) over the jointer to ensure a flat side where the bird will sit (2 minutes). Now, I have to change the bit on the router to form the outside of the flute (another 3 minutes) and run the piece through the router 4 times (4 minutes). I now have what I refer to as a blank - a flute with no holes. So far this process has taken less than one hour. Forming the sound hole and the flue can take up to one hour, depending upon the hardness of the wood. This is the most important aspect of flute making and there is no compromise on time. I use hand files and try to ensure a tight and perfect airflow down the flue to just the right cutting edge of the sound hole. Time is not important here but precision is critical. Some flutes come out of this stage in 15 minutes and others take much longer. Then, when the sound hole is right, the finger holes can be drilled and tuned. I have had flutes practically tune themselves and come out perfect in just a few minutes. Other flutes may take a bit longer in the tuning process. A little wood off here, a little wood off there, trying not to take too much off at once. I have made thousands of instruments and each one is just like making the first one all over again. Finally, when the flute is tuned, I sand and complete the piece. This whole process takes about 3 hours. Then there is the wood buying time and the packaging time and the waiting in line at the post office time and the talking on the phone time. But the real time is about 3 hours. On a good day, I make 3 or 4 flutes. I recommend research whenever the word "handmade" is used. Chances are it isn't "handmade". Fancy carved bird fetishes do not necessarily mean they were carved "by hand". Be very careful of very high priced flutes. Check them out. Look closely for clues as to their construction. Ask questions a listen closely to the answers when the flute maker responds. Are the answers direct? Are the answers easy to understand? Is the maker evasive about the process of creating a flute? Or are the responses grounded in the truth. I am the only person in my shop. I acquire the wood, create the flute, talk to the client, and recycle cardboard to make the package for shipping. Occasionally, I do a little inlay work on flutes that I feel are exceptional and only when I feel a need to be even more creative. These flutes are simply elegant just as they are. Check out the pictures in the rest of this site and I believe you will understand my philosophy about Tsunami Flutes.
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