Last time I showed you how I make the barrel of a duck call. This week, I am going to show you what goes into the insert. The insert is the most important part of a duck call, and the most challenging. Each call maker has many hours spent designing their insert, in order to produce the best sound possible.
The first step is to choose the blank that I am going to be using. Generally, I try to use a piece of wood that comes from the same piece as the barrell. This allows me to match the grains and colors, to have a nice uniform appearance.
After turning the blank round, I start to make the tenon for what will become the toneboard.
Once the tennon is turned to the correct size, I turn the insert around and mount it in the chuck in order to shape the exhaust end.
I turn the insert to the shape that I want, drill it, and sand it smooth.
After sanding, I apply the finish. I am using a CA finish on this call. CA, or cyanoacrylate, is basically super glue that provides a very glossy and durable finish.
After applying the finish, I buff it to a nice shine.
I sand and file the toneboard, cut the reed, and cut some cork to do the final tuning. Every little change that I make, changes the sound produced by the call.
The insert has been tuned and is ready to call in the ducks.