I start by cutting a 6″ piece of 1″ acrylic (I do it the same for wood, antler etc).  I then mark the center of each end using a center finder and then use a center punch to make a dimple.

I mount the 1″ x 6″ piece of acrylic on the lathe and turn a 5/8″ x 2″ tenon on the side closest to the headstock so that it will then fit into my collet chuck.

The acrylic mounted in my collet chuck.

I now turn all but the end piece (of which I am going to shape later) down to 5/8″.

Drill a 1/4″ hole for the tone channel.  I mark the distance on my drill bit and use a drill stop collar.  I use a pan underneath to catch all of the cutting lubricant that I use.

Turn the end piece to your desired shape and cut your lanyard groove.

Wet sand the piece using a lot of water and sanding pads from 600 grit to 12,000 mm.

Polish the inside of the insert using a .22 rifle cleaning swab and extension.

Polish the outside of the insert.

Use a parting tool to cut a deep groove next to the collet chuck.

Snap the insert from the collet chuck.

Mount the insert into a duck call jig.

Cut the end and excess material from the jig.

Ready for sanding, polishing and installing reed and cork.

If you want a drill bit that will cut through your acrylic duck call barrel blanks with ease and exit the blank without chipping, then this is the one you’ve been looking for!  This drill bit will also drastically minimize your duck call barrel bore sanding as well.  You can purchase it at Webfoot Custom Calls.

I have used it numerous times for drilling my acrylic blanks and highly recommend it!  Here is the full product description: