Okay, I’ve gleaned the following from some of the top instrument makers:
One simply can’t come up with a design that works in one key and then crunch the numbers to come up with the perfect specs for every other key, it just doesn’t work out perfectly in the end. Seems that following the numbers (as Thomas suggests) will only get you so far - then a whistlemaker’s experience, intuition and finally experimentation come in. Move a hole a little bit here, change the bore dimension a tad there, fool with the windway a touch…each time you mess with one of these you run the risk of having to readjust other things to keep it all going in the right direction. There are really infinite number of combinations of hole sizes, placements, amount of undercutting, window and windway size and shape, as well as bore diameter and wall thickness to mess with.
So…It seems an instrument maker will first focus on developing the best High and Low D they can because those are the most in-demand keys. They they’ll try to use the same headjoint and tube diameters etc. to knock out a couple of other keys (Eb and C are common) without spending a lifetime trying to find the optimum design for each key. Then, when they get to the point where performance becomes unacceptable (say by trying to make a Bb using the same bore diameter and head joint they optimized for a D whistle) the pick another key to start more or less designing from scratch.
Look a Sindt Whistles for example: One head joint and tube size for Eb and D, then John designed a separate C whistle with different sized tubing and headjoint. He did this, I’m sure, after trying to make a C whistle and with the D headjoint and tubing. John likely found the D design just wouldn’t work all the way down to C, so he built something new, realizing the the A and Bb whistles would have to be different (from the C) as well, but he knew the A and Bb could use the same headjoint and tube.
So, all of John’s whistles work very well (like them or not the do work exceptionally well), because he decided not to stretch the limits of each design too far. OTH, there are plenty of examples where the maker chooses to make an extreme stretch and the whislte’s playing characterestics suffer significantly - the old style Susato narrow bore A whistle immediately comes to mind, not a fun or rewarding whistle to play because it they had just strecthed a good design (for a higher whistle) too far. Eventually Susato redesigned the whistle and I’m sure it’s much more in line with the rest of their products now, in terms of performance.
Anyway…Ideally each key of whistle would have it’s own unique design, but very few makers would have the time or energy to mess that sort of R&D, especially if they have any sort of waiting list, so what we get are compromises that we have to accept.
Okay, so that’s what I learned on my summer vacation 
Loren
[ This Message was edited by: Loren on 2001-12-17 17:45 ]