I know there are several tutorials up on how to make toneboards. I just wanted to post up how I do it. I'm not saying this is the right way or the best way its just what works for me. Hopefully, someone may pick something up off it as well. So here it goes. I apologize before hand about the messy shop.
I start off with a 1/4'' drill bit in my chuck. I got my chuck off amazon.com for like $15 and it has lasted me for a while.
I cut my blank at 4" I don't know why 4" It's just what I have always done and it works for me. I know, I know I have small hands
I find center on both ends of the blank and drill the insert hole on my lathe at its slowest speed. I don't drill all the way up the bit so I can easily sand the end of the insert later.
Once I get the blank to the desired spot on the bit I get the blank turned round.
I then hold my jig up on the blank figuring up on how much bell I want sticking out of the barrel.
I then mark the edge of the jig where I want it to fit into the barrel at and mark where I should start increasing diameter at on the insert. The fat line is for the increasing diameter and the skinny line is roughly where the insert will stop at in the barrel.
Then I turn the end down to slightly larger than 5/8" up to the fat line on the blank.
I then slide the tailstock back and put my jig on the insert to see if its the same diameter as my jig. I don't worry about taking too much off sanding cause I figure I put back on in finish what I have sanded off.
Once I get a good fit on my jig I turn my insert down to its basic shape.
After I get the insert to its basic shape I then slide the tailstock back again and put a barrel on the insert to see how far the bell will stick out of the barrel. If its too far I shave a little more off of it so it fits exactly where I want it to.
With the barrel on the insert I mark a line where I want my lanyard groove to go on the insert. I usually put it approx. 1/4" down the insert from the barrel.
I then cut the marked line out into a lanyard groove.
Once this is done I apply my finish to the call and take it off the lathe and put it in my jig.
I then cut the insert out on a bandsaw leaving about 1/16" of soundboard to file on so I don't dull my blade. Then I file it down where I want it.
Finally once all that is done I slap the insert into the barrel and its ready to go. After much needed tuning of course. Like I said before, there is 153 ways to make an insert. This is just the way that works for me. Hope it helps some of you guys that are wanting to start making your own inserts. This is the finished product "Lignum Vitae"
