Cool - I just now read those comments as well. Before I had just watched the replay, ignoring the comments, and Kristen had pushed your first comment into the live stream.
I was very disappointed I was unable to play that bad boy flute the way I wanted. I was playing through two Surge XT Treemonsters - one down 1 octave, the other 2 octaves. Natively the flute’s fundamental is B2. So with Surge it was playing B0 and B1 - a totally killer sound. Solo it was sounding great before the broadcast, but in that basement and with the other instruments it just became mud. Plus I think I was getting destructive interference in my corner of the basement, making it even harder for me to hear. So I quickly gave up and switched to the djembe.
Someday I may make a video showing how the flute is constructed. The design borrows some ideas from others, and then I throw my own tweaks to get more power from the flute.
I used the following for design inspiration:
But that design has much too small a sound hole for my taste - it chokes off the sound. For my sound hole I wanted 1" wide and 1/2" tall, which required a significant design change. I cannot simply shave off just the inner tube for the flue and get that width.
My flute head has a 1.5" coupler and a 3" coupler acting as outer sleeves, with a ~2.25" long inner section mating them together. The sound hole is cut through both the lower coupler and the inner tube, giving me much more thickness to work with. For the flue I not only shaved off the top of the inner tube, but also took away material from the inside of the coupler. And the fipple is angled on both the outer and inner surfaces - shallow on the outside, steep on the inside. It ends up looking more like a pipe organ.
The bocal construction is basically as Blue Bear shows, and I also used a test cap to divide the slow air chamber from the body of the flute as he shows.
Of course my finger holes are totally different - lots of educated guesswork and undercutting. The holes are so far spread apart I must use both thumbs, plus my index and ring fingers, with huge offsets to match the curve of my hand.
I don’t know how I would have made the flute without my Dremmel.
Somehow I managed to make it all work my first try (though I did fill in some finger holes and re-drill a few times until I got the tuning right). I haven’t made another one since.
I had dreams of a more massive flute one octave lower, using 3" PVC. The flute head turned out fantastic - it provided a gorgeous powerful tone with a 4 foot pipe body. But when I add pipe to the desired length it just becomes too much air to move. By the time the sound stabilizes, I am out of breath. So I gave up on that design.