Now that you have the measurements it is time to actually shape your metal to match them. Cut the tube to the desired lengths and file or sand off any burs. The fipple hole can be cut any length down the mouthpiece, it is only the distance down from that point that affects the flue's sound. Cut the fipple hole with the end mill and file down the lip. You'll have to bend the lip in slightly so that it is near the bottom of your fipple plug channel.

To form the fipple plug trim aluminum stock to the interior diameter of your tube on the lathe. Grind off a few millimeters on one side, which will be the top. Then cut a channel with an end mill. This channel ended up deeper than stated on the previous sketches, about 15-20mm. A deeper channel produces a louder flute, but a narrow channel produces a cleaner sound.

Forming the body is a simple matter of drilling appropriately sized holes in the correct spots. Be sure to go one size down from the recommended, it will give you some leeway to make changes.

Finally the mouthpiece and body are connected with an aluminum tube cut with the same inner diameter as the outer diameter of the brass tube.

