# Assembly Manual

## Safety And Setup

- Wear eye and lung protection when drilling, routing, sanding, or turning.
- Do not route a long round blank without a stable V-block or split-blank fixture.
- Keep the splitting edge protected until final voicing.
- Mark the labium datum, foot datum, bore centerline, and back thumb-hole line before any irreversible cut.

## Prototype Ladder

### P0: Fipple Head Tile

1. Cut a 4 in scrap block with the selected bore diameter or a half-bore test channel.
2. Cut the end mouth inlet.
3. Fit a removable flue plug with 0.033, 0.038, and 0.045 in shim trials.
4. Cut a side true sound window and splitting edge.
5. Blow through the end inlet and record which plug/window combination speaks cleanly.
6. Do not build a full flute until this tile produces stable tone.

### P1: First Kaval Body

1. Select `KAV-A3-5H`.
2. Mill the blank overlength by at least 2 in.
3. Split the blank, route the bore halves and registration pin holes, or deep-bore the solid blank after proving setup on scrap.
4. Create the fipple head and removable plug.
5. Prove the root tone with no finger holes.
6. Trim the foot to bring the all-closed root toward A3.
7. Transfer hole positions from `kaval-hole-schedule.csv`.
8. Drill each hole undersized.
9. Tune holes from the foot upward by reaming slowly.
10. Record every before/after pitch in `validation.csv`.

### P1: First Alghosazi Body

1. Select `ALG-AS3-J2`.
2. Build as a solid body first if joint risk feels high; otherwise cut the two-piece joint after the bore is proven.
3. Mark the rear thumb-hole line before drilling.
4. Drill the thumb hole undersized and validate reach with the actual player grip.
5. Tune the primary sequence and record whether the scale feels musically right.

### P2: Jointed Version

1. Cut the body overlength and prove tone before final jointing.
2. Locate the joint away from holes and away from the fipple head.
3. Turn tenon and socket with a 1.25 in engagement target.
4. Add cork or waxed thread until the joint seals without force.
5. Check bore step with a dowel, light, and feeler test.
6. Re-test root and all holes after the joint is fitted.

### P3: Double Drone

1. Build melody and drone tubes separately.
2. Tune the melody side alone.
3. Tune the drone side alone, including rear thumb vent if used.
4. Join the bodies temporarily with clamps or bands before permanent collars.
5. Test pressure sharing with both windways.
6. Only then commit to a permanent double-body fixture or decorative binding.

## Finishing

- Finish exterior after tuning.
- Keep heavy oil, shellac, and wax out of the windway and splitting edge.
- Seal bore lightly only after final measurements.
- Recheck pitch after finish cure.

## Maintenance

- Let the bore dry after playing.
- Remove the fipple plug only if the design uses a wax-sealed removable plug.
- Do not store jointed bodies assembled under high humidity swings.