Initial Blank Size
I am cutting the blank to the following specification on the band saw:
Width: 46mm
Height: 50mm
Length: > 750mm (I am using 950mm which contains approx. 100mm margin at the mouth and end piece)
For the specific demo project in the pictures I used 3 pieces of wood. Maple for the mouth-/end piece and walnut for the middle.
Planing
I use a thickness planer to reduce the width to exactly 42mm and have two parallel smooth sides. I do this by planing one side until it is smooth and all sawing marks are gone. That usually reduces the width by about 1mm to 45mm. I then turn it around and plan the other side until I have a width of exactly 42mm. I use a digital meter to measure the sizes exactly.
Now the other two parallel sides:
The target is to have a height of 46mm with both sides being smooth. Again planing one side until it is smooth and then the other side until I have 46mm in height.
As you see in the picture I used more margin in blank length than needed because my planer does not do well with the ends (approx. 50mm on each end are beveled). Using more margin allows me to cut off the ends after the planing process.
I have simply glued the different wood pieces together. This might not be the most sophisticated way to connect them but so far I have never had an issue with parts coming apart. Just make sure to use denaturated alcohol to clean the surfaces, use good glue and a long clamp. The glue seam looks very good to me (see picture).
Splitting and Planing Again
I use my band saw to cut the blank exactly in the center (length wise) to have two halfes that are 42mmx21mmx>750mm each. By sawing with a 1mm blade, I am loosing 1mm in the middle of the blank which leads to 22.5mm for each half after sawing.
Right after sawing I use my FriXion pen to write “top” or “bottom” on the respective half. That will help later not to confuse the orientation.
I also write the year, month, day and number (of flute that day) on each half just in case I build more on one day so I don’t mix them up.
Now I use the planer again to smooth the “inner” sides of the halves to get rid of the sawing marks (not more!). This leads to another loss of 1mm on each inner side of the blank halves.
We should end up with a height (thickness) of 21mm of each half.
