How to Build an Irish Penny Whistle

Creating a penny whistle can be a challenging, yet fun process. The result of some careful measurements and tweaking can be handmade and completely playable musical instrument.

Things You'll Need

• 1/2-inch plumbing pipe (avoid copper)
• 5/8-inch dowling
• Copper pipe connector to fit 1/2 inch pipe
• Hacksaw for metal
• Metal punch
• Ruler or calipers
• Permanent marker
• Drill with bits 17/64-inch, 3/16-inch, 15/64-inch, 13/64-inch, 7/32-inch
• Metal file
• Sandpaper

Instructions

The Fipple

1. The fipple is the mouthpiece of the penny whistle. To create one, start by cutting a 3.5 cm length of plumbing pipe.

2. Slide the connecting sleeve onto the pipe, putting about half of it on the pipe. Use a metal punch on each side of the connector to secure the two pieces together.

3. Use the marker to mark a spot 2.45 cm from the bottom of the sleeve. Use the drill with 7/32 bit to drill a hole on this spot through both the sleeve and the pipe.

4. Use the metal file to turn this hole into a rectangle approximately .75 cm x .5 cm in diameter. The hole should end about 2. 2 cm from the end of the sleeve.

5. 

   Reduce the doweling to a size that fits inside the pipe. Sand away at the doweling until it fits snugly inside the pipe, not the sleeve. The goal at this point is to turn the piece of doweling that measures 1 inch in length, .9 cm in width at one end, .75 cm in length at the other end and has a flattened side. Once sanding has made a piece this size, a channel must be carved down the center of the flat end. This should measure about .9 cm at the thick end of the dowel and .75 cm at the thinner end.

6. 

   Find a flat hard item, such as a piece of doweling or the flat tip of the metal punch, that fits just into the hole. Angle it as illustrated and tap it down just enough to bend the metal at the end of the hole about 2mm downward.

7. Insert the carved dowel into the pipe end of the fipple, thinner end first.

8. 

   Use the hacksaw to cut an angle onto the pipe end of the fipple, using the shape pictured. This will cut through both the pipe and the wooden dowel. Use the file and sandpaper to create a smooth surface, since this will be the end that goes into the mouth.

9. Test out the fipple. It you blow into the angled end, it should produce a whistling sound. If it does not, check the fipple's hole to be sure it is slightly open and use a screwdriver or end of the file to open it if necessary.

Build the Body

1. The body of the penny whistle is much easier to build than the fipple. Begin by cutting a piece of piping about 12 inches in length.

2. Use the marker to mark where the drill hole will be. Start at one end of the pipe, which will be the bottom, and measure up for each of the drill holes. Mark at each of the following points from the bottom: 4.25 cm, 7. 05 cm, 9. 25 cm, 11.65 cm, 14.05 cm and 15.25 cm.

3. Drill to cut the correct size hole for each of these marks. Starting at the bottom, use the bits in the following order: 17/64-inch, 17/64-inch, 3/16-inch, 15/64-inch, 15/64-inch and 13/64-inch.

4. Slide the fipple over the top of the body. Test it out and enjoy your new penny whistle.

Tips & Warnings

• To test the tuning of the whistle, place the fipple over the body before cutting the holes. It should ring as a "D" before any holes are cut. If it is flat, or below the "D," cut the pipe down a bit until it rings in tune. If it is too high, your pipe is not long enough. It is best to start with a too-long piece and work your way down. If the tuning is only slightly too sharp, or above the note, this can be adjusted by pulling the fipple out from the body. If the fipple is too loose to do this, it can be tapped with a hammer very lightly to make it fit tighter. To adjust tuning on the remainder of the whistle, use a small file to enlarge the holes carefully.

• Always file down the pieces of metal as they are cut to avoid spurs and cuts

References

• How to make a feadog
• How to make a penny whistle