BANDSAW

My Powermatic bandsaw came with a 4” dust collection port built into the back of the unit.  While it catches a lot of the dust and debris from the materials that I use in making a duck call, it does not catch it all.  As you will notice in the pictures I added a Stay Put Hose Kit and Stay Put Hose Bracket so that I can now capture a lot more that comes from the blade area on the top of the table.  This works great and I am well pleased.  I have also seen pictures where the hose was installed on the back of the bandsaw and the Stay Put Hose was routed over the top and down beside the blade.  This will also work but be sure to purchase an extra Stay Put Hose Bracket.

DRILL PRESS

Like all drill presses, my Powermatic drill press did not come with any dust collection hook ups.  I added the same Stay Put Hose Kit and Stay Put Hose bracket that I used on my bandsaw.  This eliminates virtually 99% of the dust and debris that are generated while I am boring the holes into the body and insert of a duck call.

SANDERS

As you can tell, I really like having several sanders with various grit belts and pads when sanding the duck call.  I have the dust collection designed so that I can restrict or increase vacuum pressure to each machine.

DUST COLLECTOR

I have been making duck calls for many years and in the past was limited to a small dust collector that only had one port.  Therefore I would have to disconnect the hose from the unit every time I used a separate machine.  Once my new shop was built, I researched every dust collection system known and finally landed on the CV 1800 LH 1P Cyclone Bundle with Filters from Clear Vue Cyclones.  If I had it to do over again I would purchase the exact same system!  It is powered by a 5 HP Leeson motor and has a 6” inlet that reduces down to the standard 4” at the machine.  It definitely has more than enough suction!  The folks at Clear Vue are awesome to deal with and were available by email and phone anytime I needed assistance.  I highly recommend them!

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.