Jerry,
Since the tweaked whistle I sent you seems to have really got your tweaking juices going, let me explain a couple of things.
First, I got the heat tweak idea from Brother Steve (StevieJ) who posted a thread about it some months ago, and he answered some of my questions in chat before I actually had the guts to start holding my fipples over a powerful heat source.
Steve, btw, tells me that he originally got the idea from Debbie Quiggley, a great pipes & whistle player from (I believe) Toronto.
Here is StevieJ’s original thread:
http://chiffboard.mati.ca/viewtopic.php?topic=3434&forum=1
I feel a bit guilty now, because the tweake Gen D I sent you is not the best tweak I’ve done. It was one of the earlier ones and I was pretty happy with it. But I have since produced one (maybe two) better ones. The thing I was not totally happy about with the whistle I sent you is that because of the way the plastic heated and softened, it is compressed right at the mouth-end of the windway. I was trying to reduce the size of the blade-end of the windway. That is not really possible unless you press the roof of the windway in, which I did not want to do. But I have since managed to compress the middle of the windway, and the results are a bit better and a bit less prone to clogging.
Two points fyi:
There are people who tweak their cheapos in the following manner (I haven’t tried it): Take some rigid plastic, like a bit of guitar pick, cut it to the width of the windway and glue it to the top of the windway, where it opens onto to the window. That reduces the windway opening opposite the blade. I understand that very little can have a significant effect. I guess that the tweak will create backpressure, and probably increase the purity of the tone. (Potential problem here is that you want the edge of the blade to divide the air stream roughly in the middle—I’ve read 55% above/45% below—and if you just narrow the windway from the top, you are messing with the blade placement vis a vis the windway.)
Nothing has given me insight into the factors controling breathiness/purity, volume, balance between octaves and so forth as tweaking my Susatos. I cut away the curved blades and replaced them with a straight guitar pick blade. I spent quite some time moving the new blade around moving it closer to the windway or further from it, making the blade’s angle steep or shallow, bevelling the edge of the blade in different ways with a nail file. Very interesting, especially if you realize that a fraction of a millimeter can complete ruin the voice of the whistle, as can a poor bevel on the edge.
Here is the Susato tweak thread:
http://chiffboard.mati.ca/viewtopic.php?mode=viewtopic&topic=7282&forum=1&start=15