As I mentioned a bit earlier in another thread, I rather like working with PVC now that I’ve gotten used to it.
All my recent prototype whistle heads have been made from PVC with Delrin fipple plugs, and I’m really of the opinon that the combination will suffice for production runs as well.
I know there have been heated debates in the past regarding the safety of putting PVC in your mouth, but if it is safe enough to carry drinking water, I have no hesitations with making whistles from it.
For that matter, there have been heated debates about the safety of putting aluminum in your mouth as well, but I have more worries about the fillings in my teeth than I do about putting aluminum in my mouth. 
I know several whistle makers have had a great deal of success with their PVC whistles, so I’m very optimistic that my PVC/Delrin heads will be successful and accepted by most whistle players.
PVC is dirt cheap and readily available locally, which allows for cost savings that can be passed on to the consumers.
PVC also doesn’t require center drilling since it is already pipe and just needs to be made concentric with a boring bar, which eliminates a major step in the production process that is necessary with bar stock… which translates into yet more cost savings that can be passed on to the consumers.
Does anybody think I’m making a terrible mistake in my choice of materials?
I can make a solid Delrin head… or nylon, teflon, aluminum, brass… you name it.
If nobody objects though, I’ll continue refining my production methods with PVC, and begin production of PVC heads with Delrin fipple plugs very soon.
For reasons you mention, PVC is ideal. Just remember to wear a good quality filter mask when maching or sanding.
I agree with Tony. Go ahead and use PVC. That’s what M&E flutes are made out of (they’re not Delrin), but his does come in a rod form which requires working as if it was a piece wood.
You’re right, M&E Flutes are made from a solid rod of PVC that is turned and bored. A Woodwind Quarterly magazine of a few years ago had an article on his flutes.
PVC works well in the Schedule 40 grade, note that there is a thin wall (Sched.20) and a super thick wall (sched.80) grade as well.
Also, you can turn sockets and tenons on Sched.40 or higher. I’ve made some whistles with the last tonehole rotatable for short fingers.
PVC’s fine by me.
PVC is great. Two of my favorite (don’t ask how many ‘favorites’ I have) are made of it. You can always expand your models in the future.
Frank
Gary, you do quality work, no doubt about it, but there are others ahead of you in PVC. I’d love to see you make something no one else makes, and to your own high standards. I don’t have any ideas for you, just that observation.
If it’s goodenough for Glenn Schultz’s Water Weasels, it’s good enough for me
I like the PVC/Delrin combo. I’m also curious as to the differences in working with PVC and Delrin; Chris Abell makes whistles in Delrin that sound every bit as good as his blackwoods.
Regards,
Philo
Nylon,Polyethylene and Acrylic resin tubing is less common but these are available from plastics supliers. Clear/Dyed Acrylic has a nice tone (pure/hard) and cuts well on the lathe with sharp tools. I cast Acrylic resin over polished copper tubing in some of my panpipe sets and then cut facets for a sun-catcher sparkle. I’ve never made a tin whistle like this though(hmmm,loose bolts and metal sound).