I’ve had the whole day to work with my new shop tools and experiment with improving my head design, and I’m very happy to say that the idea I came up with to reduce my head assembly to three pieces worked amazingly well!
The new design will be easier to produce since it eliminates two pieces from the fabrication process, and it will now be impossible for me to get the blade out of perfect alignment with the windway since they will now be made together.
Unfortunately I still have to get a “real” boring bar, since the 7/8" depth boring bar that came with my lathe is not long enough to bore the outer sleeves… but I should have it before next weekend, so it isn’t a major setback.
I’ve been working with CPVC while I learn to use my new tools instead of wasting my good Delrin and aluminum stock, but I’ve really grown to like the stuff.
It machines really well at low speeds, so I’ll be using it for more than just practice… there’s no reason why I shouldn’t make CPVC whistles, or at least CPVC heads with Delrin fipple plugs.
I’m extremely optimistic about maybe having a batch of retrofit Eb/D heads finished within a matter of weeks unless something unforseen happens.
I feel like a kid at Christmas now that I have the proper tools to become a serious whistle maker… or maybe a whistle junkie that can now support his own habit is a more fitting description of the way I feel! 
Stay tuned for further updates…
Awesome . . . keep us posted please.
Awesome! I think this is a good opportunity to let you know that i’m now accepting whistles on temporary or permanent loan for testing. Send me the pretty whistles! 
The line forms..right behind me…
Ahhh, and this is where the information gained from the thread about Whistles of Mass Defenestration comes into its own …
starts discreetly bopping off the queuers
Loving reading this stuff, Gary, more please! It’s fascinating to this non-tool-enabled-but-wishful-thinking squeaker.
Tell us more about this boring bar Please 
What kind of tip does it have? Can you show us a pic, where are you getting it from?
Another way to bore out the external coupler is to use the large 7/8" wood boring flat bits. By using a grinder, a little material is taken off of the bit on each side and you can bore out a coupler in about 1 minute.
I finally got my “real” boring bar this evening… I should have got it Wednesday evening, but UPS somehow managed to lose one between Chattanooga and Sparta. :roll:
As usual, Stacey’s is bigger than mine… but it’s not how big it is, it’s how you use it! 
Here’s a pic for the tech-heads… and for those of you who are unusually aroused by tools!
