# Irish Flute Assembly Manual

## Build Gates

1. Build and measure the scrap bore before touching tonewood.
2. Cut the embouchure and verify a stable edge tone before drilling tone holes.
3. Drill one tone hole at a time, then measure. Opening a hole raises pitch and cannot be undone.
4. Apply bore finish before final tuning measurements.

## Procedure

### 1. Stock Prep

Select straight-grained, stable stock. Crosscut the tonewood blank and the scrap blank to 24.50 in. Mark centerlines on all four faces and both ends.

### 2. Scrap Bore Validation

Mount the scrap blank using the planned bore setup. Bore to 0.750 in ID with conservative feed and frequent chip clearing. Measure exit wander and bore diameter. If wander exceeds 0.030 in, revise the setup before proceeding.

### 3. Tonewood Bore

Bore the actual blank only after the scrap process passes. Record bore diameter at entry, mid, and exit in `validation.csv`.

### 4. Turn Exterior

Use the bore axis as the datum. Turn the exterior to about 1.000 in OD, leaving local shaping around the embouchure area until voicing is stable.

### 5. Embouchure

Cut the transverse embouchure conservatively. Bevel the far edge and test for a clean edge tone. The embouchure is an acoustic feature, not only a drawing dimension; refine on the scrap blank first.

### 6. Fundamental Check

With the embouchure speaking, measure the all-closed D4 target before tone holes are drilled. If the tube is flat, trim from the foot in small increments. If sharp, stop and document the error before continuing.

### 7. Tone Holes

Lay out holes from the foot using `design.md`. Drill undersize, beginning with hole 1. Measure the note, then open or undercut gradually. Repeat through hole 6.

### 8. Finish And Final Validation

Apply bore oil or shellac, allow it to cure, then remeasure the fundamental and each note. Populate `validation.csv` with measured pitch, cents error, temperature, and notes.