The wooden plug in my Clarke whistle is loose 
- moves up and down slightly. What is the best way to fix it and should the wood be flush with the metal at the mouthpiece? Thanks
Hi, Clare.
You can take a hammer and nail and punch one or two new dimples into the sides of the metal to grip the plug better, or you can drill through the metal and plug and pin it with a small nail or brad.
Where the plug belongs is a matter for experiment. Try it in different locations until you find where it sounds best. A tiny difference in the location of the plug can make a big difference in how the whistle sounds, especially in the upper register.
Best wishes,
Jerry
I have a Clarke C that had the same fate. Jerry’s idea of pinning it in place is a good one. I was hesitant because I didn’t want to pin the plug in the wrong place (the plug was moving up and down a bit), so I popped a shortened toothpick underneath and wedged it around a bit until the sound was good. In with the pin, out with the toothpick, a tightening with the trusty vice grips to remove the gap under the block, and the rest is history.
While I’m at it, thanks to you, Jerry, for sharing your tips with us!
Jef