begin construction prepare 5 varying diameter lengths
of pulled sprue 10 cm long or more.
1 x very thin
diameter (like 1 lb test) for the micro dots.
1 x thin diameter (like 4 LB test) for the steam pipe
1 x small diameter sprue for the small whistle bodies.
1 x medium diameter sprue for the medium whistle bodies.
1 x large diameter sprue for the large whistle bodies.
the individual pieces for each whistle assembly.
- Cut 4 x
3.5 mm lengths of the largest pulled sprue and set aside.
- Cut 4 x
2.75 mm lengths of the medium pulled sprue and set aside.
- Cut 4 x
2 mm lengths of the small sprue and set aside
You now have
all the whistle bodies made.
To make the
bolts for each whistle use the very thin pulled sprue
and cut/slice a small tab off of the end so you have a
tiny pieces less than a grain of salt in size. Make twelve
of these (and extras in case you lose some). Set these
whistles had rounded flare bottoms that sat on the pipe
coupling. This requires a bit of finesse but can be achieved
will need a constant heat source. We used a stubby broad
based candle held inside of a Testor's spray paint plastic
lid for safety.
you have the thin sprue handy, light the candle and prepare
to make the flared whistle ends. Make these one at a time
as they require molding, cooling and cutting. Repeat the
process for the next one.
the thin sprue about 6-8 cm off to the side and above
the tip of the flame. Move the sprue in from the side
very S-L-O-W-L-E-Y to place the rod into the heat plume
thrown off by the flame. This allows you to control the
diameter of the flare being created.
whistles being different diameters require different sized
Use the small diameter sprue and as soon as the sprue
begins to flare pull it back and allow to cool. Once cooled
remove the flare from the pulled sprue `rod' with your
hobby knife and set aside. Repeat this three more times
for the other whistles (make a few spares in case you
Use the medium diameter sprue and repeat the process for
the smaller bases but leave it in the heat longer, then
pull it back, let cool and cut off. Repeat three times.
the large diameter sprue and repeat the process for the
medium bases but leave it in the heat for longer again.
Repeat three times.
assemble the whistles.
the thin pulled sprue made for the steam pipe coupling
and place it in front of you.
the other parts and place them in their groups. In each
group you should have:
x small whistle body
1 x medium whistle body
1 x large whistle body
1 x small flared base
1 x medium flared base
1 x large flared base
3 x microdots
DO NOT CUT the pulled sprue steam pipe to length yet as
this will make handling easier. Add a small dab of glue
along the first 4 -5 mm. Place the three flared ends with
their round end down as follows: SMALL - LARGE -MEDIUM,
with the small flare on the end of the 'pipe'.
can glue the large flare into the center first and then
add the medium and small on either side, whichever is
most comfortable for you.
Once the 3
rounded flares are dry, add a dab of glue to the top of
each flare and place the appropriate whistle body to its
flare (small/small, large/large, etc.).