Kaval + Alghosazi Fipple Flutes Capstone Print Packet

Generated: 2026-05-05

Packet folder: `/mnt/c/Users/Tony/Documents/GitHub/kaval-alghosazi-flutes`

File Map

design.md

Project intent, catalog metadata, assumptions, and validation plan.

Kaval + Alghosazi Fipple Flutes

**Packet ID:** KAV-ALG-FAM-001

**Family:** open-pipe woodwind / duct-fipple flute

**Pipeline:** cnc-lathe hybrid: split blank or deep bore, fipple head, lathe rounding, optional two-piece joint

**Date:** 2026-05-06

**Done-bar references:** `fujara`, `flutes`, `drone-flutes`, `pistalka`, `transverse-flute`

Project Intent

Design a buildable family of long fipple kavals and Alghosazi flutes that feel close to the Fujara Flutes references while using Tony's existing fujara/flute workshop logic: parametric dimensions, a controllable fipple sound-window head, split-blank CNC or deep-bore construction, validation tables, and documented tuning loops.

The first physical goal is not a perfect production run. It is a controlled prototype ladder: prove the fipple head, build one A3 5-hole kaval, build one A#3 Alghosazi with a thumb hole, then decide whether the two-piece and double-drone versions deserve full CAD.

Source And Scope

External reference pages checked:

• Fujara Flutes Kaval page: 5-hole fipple kavals, 7-hole expanded kavals, lengths from about 62-90 cm, and double Kaval/Kavalghoza drone concept.
• Fujara Flutes Alghosazi page: fipple adaptation of Anasazi-style flute, top hole moved to the back as a thumb hole, lengths from about 70-85 cm, and a double-drone option.
• Flutopedia Anasazi tuning notes: used only to justify the Alghosazi starter offset set as an Anasazi-derived primary sequence.

Local source artifacts inspected:

• `fujara/design-table/fujara_equations.md` and SolidWorks dimension extracts for fipple/flue plug geometry.
• `drone-flutes/design.md` and `flutes/skills/parametric-design-table.md` for open-pipe, shop, and validation workflow.
• `pistalka/docs/build-packet/design.md` for a compact fipple-flute build sequence.

Governing Model

These flutes are modeled as **open-open cylindrical fipple flutes** with a non-NAF fujara-style sound-window end correction.

f = c / (2 * L_eff)
c = 13552 in/s at about 68 F
L_eff = physical_labium_to_foot + foot_end_correction + sound_window_correction
foot_end_correction ~= 0.6 * bore_radius
sound_window_correction = measured prototype value, not Tony's NAF K2 table

For first-pass hole placement, the packet uses a proportional open-pipe layout:

x_from_labium = labium_to_foot * 2^(-semitone_offset / 12)
x_from_foot = labium_to_foot - x_from_labium

The hole schedule is intentionally a **starter drill schedule**. The builder drills undersized, tunes the root by trimming the foot, then opens each hole upward by careful reaming/undercutting. If a hole goes sharp, the recovery is wax test, bushing, or a rebuilt body.

`family-spec.csv` includes `estimated_sound_window_correction_in`. Positive values mean the fipple/window system or added acoustic path must make the instrument behave longer than the visible labium-to-foot length. Negative values mean the source-observed body length is overlong for the nominal root under a simple open-pipe model; treat those as overlength blanks to trim or as evidence that the commercial key naming may not equal the all-closed root.

Scale Plans

5-Hole Fipple Kaval

The 5-hole kaval follows the published C-reference pitch set:

0, +2, +3, +6, +7, +8 semitones
Example in C: C D D# F# G G#

7-Hole Fipple Kaval

The expanded kaval adds the two half-step options described by the reference page:

0, +2, +3, +4, +6, +7, +8, +9 semitones
Example in C: C D D# E F# G G# A

Alghosazi

The Alghosazi starter scale uses an Anasazi-derived primary sequence. The top hole is placed on the back as a thumb hole, matching the design note from the reference page.

0, +2, +4, +7, +9, +11, +12 semitones
Example in A#: A# C D F G A A#

This is marked as a musical-design assumption. If Tony wants a different Alghosazi mode after listening to examples, change the offsets in `Kaval-Alghosazi-Design.xlsx` and regenerate `hole-schedule.csv`.

Fujara-Style Fipple Head

The requested head architecture is:

mouth at end -> rectangular inlet -> internal windway/flue -> side true sound window -> splitting edge -> main bore

Starter dimensions:

Two-Piece And Double Options

The two-piece option is a **shop convenience and tuning risk**, not a decorative afterthought. Use it only after a solid prototype speaks well.

• Tenon engagement: 1.25 in minimum.
• Cork compression: fit by sanding; no forced assembly.
• Joint location: avoid placing the joint within 0.75 in of a tone hole.
• Bore step: less than 0.005 in at the joint after final sanding.
• Ferrule: recommended for A/A# bodies and double-flute assemblies.

Double-drone versions are documented in `double-drone-spec.csv` and `drawings/double-drone-layout.svg`. Each side gets its own windway so the melody flute can be played alone and the drone can be tuned independently.

Family Table

See `family-spec.csv` for the source of truth. The core starter members are:

Manufacturing Path

Preferred path for the first two prototypes:

1. Make a removable fipple-head test tile from scrap.

2. Build a split-blank body so the bore, windway, and window are visible and correctable.

3. Glue and turn only after the fipple speaks.

4. Drill holes undersized from a laser/CNC template or V-block setup.

5. Tune root first, then holes from foot upward.

6. Record measurements in `validation.csv` and update the next prototype.

Deep-bore drilling is allowed for later solid-body builds. Use the skill reference `headstock-driven-deep-bore-drilling.md` before attempting a long solid blank.

Assumptions

• A4 = 440 Hz.
• 68 F speed-of-sound baseline.
• Website lengths are used as precedent dimensions, not guaranteed acoustic formulas.
• Alghosazi tuning is a starter interpretation based on contemporary Anasazi-tuned six-hole practice.
• Tone hole positions ignore final hole-diameter perturbation until measured prototype data exists.
• The fipple head is Tony's derived design and must be validated by physical tests.

bom.csv

Starter bill of materials with part categories, quantities, drawing refs, and notes.

sourcing.csv

Supplier/search tracker with specs, price/date fields, lead time, substitutes, and risks.

cut-list.csv

Rough/final stock sizes, material, grain/orientation, operations, yield, and offcuts.

drawing-brief.md

Manufacturing drawing and technical product sketch brief.

Drawing Brief

Required Views

• Family overview: each member as a scaled open-pipe body with bore ID and total length.
• Hole layout: kaval and Alghosazi separate, measured from labium and from foot.
• Fipple head section: end mouth inlet, windway, flue plug, true sound window, splitting edge, bore.
• Two-piece joint section: tenon, socket, cork wrap, ferrule/collar, bore continuity.
• Double-drone layout: two bores, independent windways, melody side, drone side, thumb vent.

Datums

• Datum A: labium/splitting-edge plane.
• Datum B: tuned foot end.
• Datum C: bore centerline.
• Datum D: back thumb-hole centerline for Alghosazi.

Tolerances

• Bore ID: +/-0.005 in after reaming/lapping.
• Hole center: +/-0.020 in before tuning; final pitch matters more than nominal center.
• Windway height: +/-0.002 in once a plug speaks.
• Joint bore step: less than 0.005 in.
• Noncritical exterior: +/-0.030 in.

Drawing Outputs

Generated SVGs live in `drawings/`. Build-critical dimensions come from `Kaval-Alghosazi-Design.xlsx`, `family-spec.csv`, and `hole-schedule.csv`, not from raster images.

assembly-manual.md

Shop-facing sequence, tools, fixtures, safety, tuning, finishing, and maintenance notes.

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.

validation.csv

Target/measured values, tolerance, environment, result, and tuning/build action log.

supplier-rfq.md

Supplier email/request-for-quote starter.

Supplier RFQ Draft

Subject: Quote request for straight-grain woodwind blanks and optional ferrule stock

Hello,

I am building a small run of long fipple flutes and need stable straight-grain blanks suitable for bored woodwind bodies.

Please quote the following:

• 4 to 8 blanks, 1.25 to 1.50 in square or round, 30 to 38 in long.
• Species options: elder, locust, ash, maple, cherry, walnut, or similar stable hardwood.
• Moisture content and straightness/grain-runout information.
• Any longer stock suitable for 85-90 cm flute bodies.
• Optional thin-wall brass tube or hardwood ferrule stock around 1.25 to 1.40 in ID/OD range.

The blanks will be drilled or split-routed along the long axis, then turned and tuned, so straight grain and low checking risk matter more than figure.

Please include unit price, volume price, lead time, shipping estimate, and any recommended substitutes.

Thank you,

Tony Koop

visual-bom-brief.md

Art direction for an image-forward visual BOM.

Visual BOM Brief

Create one image-forward BOM plate with:

• hero view of a kaval, an Alghosazi, and the fipple-head section;
• item rows for body blank, fipple plug, cork/ferrule, drilling template, finish, and validation tools;
• callouts that distinguish make vs buy parts;
• source status labels: verified price, spec only, or shop stock.

Image sources:

• Use real shop photos after P0/P1 prototypes exist.
• Until then, use `images/hero.png` and the SVG drawings as concept placeholders.
• Do not use vendor or Fujara Flutes photos directly in the BOM without permission.

wolfram-starter.wl

Wolfram starter for physics, optimization, visualization, and validation.

(* Kaval + Alghosazi starter. Full v4.2 packet source is in wolfram/kaval-alghosazi-flutes-wolfram-model.wl after generation. *)
ClearAll["Global`*"];
cInPerSec = 13552;
freqFromMidi[midi_, a4_: 440] := a4*2^((midi - 69)/12);
openPipeLeff[f_] := cInPerSec/(2*f);
holeFromLabium[labiumToFoot_, semitoneOffset_] := labiumToFoot*2^(-semitoneOffset/12);
centsError[measured_, target_] := 1200*Log[2, measured/target];

README.md

Project artifact.

Kaval + Alghosazi Fipple Flutes

This repository is a build-ready design packet for two related long fipple flutes:

• a **Moldavian/Romanian-style fipple kaval** family, including 5-hole, 7-hole, two-piece, and double-drone options;
• a **fipple Alghosazi** family inspired by the Anasazi/Basketmaker long-flute lineage, with an easier fipple head and a rear thumb hole.

The head design intentionally borrows from Tony's `fujara` CAD: the player blows into an end mouth inlet, the air travels through a controlled internal flue, and sound is made at a side **true sound window** and splitting edge. The head is not copied from a commercial maker; it is a Tony-shop fujara/NAF hybrid that can be tuned and rebuilt.

Build First

Start with these prototypes:

File Map

Status

This is a first-pass engineering packet. Dimensions are parametric and source-backed where possible, but the fipple/sound-window correction is marked as a measured-prototype variable, not a borrowed NAF K2 correction.

Attribution

The kaval references come from Moldavian/Romanian shepherd-flute practice; the Alghosazi references point toward Anasazi/Basketmaker flute replicas and contemporary adaptations. This packet is a modern shop design by Tony Koop, built with respect for those lineages and explicit source notes in `sources.md`.

alghosazi-hole-schedule.csv

Project artifact.

double-drone-spec.csv

Project artifact.

family-spec.csv

Project artifact.

hole-schedule.csv

Project artifact.

kaval-hole-schedule.csv

Project artifact.

photo-shotlist.md

Project artifact.

Photo Shotlist

Follow the repo-level photo pipeline style: real process photos replace concept placeholders as soon as shop work begins.

P0 Fipple Head

• End mouth inlet before plug install.
• Removable flue plugs with shim labels.
• Side true sound window and splitting edge closeup.
• Tuner screenshot or phone photo during first tone.

P1 Bodies

• Blank selection with grain orientation marked.
• Split blank or deep-bore setup.
• Routed/bored bore before glue-up.
• Hole template wrapped around body.
• First drilled undersized hole.
• Final tuned flute full length.

Jointed/Double Options

• Tenon/socket before cork.
• Cork/ferrule fit closeup.
• Double-body temporary clamp test.
• Independent windways at the mouth end.

Finished Portfolio

• Kaval and Alghosazi side by side.
• Player hand reach shot.
• Fipple head detail.
• Validation/tuning bench shot.

risks.md

Project artifact.

Risks

Acoustic

• **Fipple/sound-window correction is unknown.** Test: build `P0-FIPPLE-HEAD`, record root prediction vs measured, and update `estimated_sound_window_correction_in`.
• **Hole positions are first-pass proportional.** Test: drill undersized and record before/after cents for every hole in `validation.csv`.
• **Double-drone windways may steal pressure from each other.** Test: record each windway alone and together; compare attack and cents drift.

Structural

• **Long solid blanks can wander while drilling.** Test: bore scrap first and measure exit offset; use split-blank CNC if wander exceeds 0.050 in.
• **Two-piece joints can leak or crack.** Test: vacuum/leak check and dry assembly force check before finishing.
• **Splitting edge is fragile.** Test: inspect under magnification after each voicing change.

Ergonomic

• **7-hole kaval lower holes may require base-of-finger coverage.** Test: paper wrap mockup before drilling final diameters.
• **Alghosazi thumb hole may not fit all hands.** Test: mark with tape, play air-grip, then drill undersized.

Supply

• **Elder and locust blanks may be hard to source in required lengths.** Test: verify supplier stock before committing scale/key; use ash/maple/cherry for prototypes.
• **Ferrule dimensions may not match body OD.** Test: choose ferrule after body OD is turned, not before.

Fit And Finish

• **Finish can clog the windway.** Test: mask windway and splitting edge; recheck attack after cure.
• **Cork compression changes with humidity.** Test: assemble/disassemble after overnight humidity change and record fit.

sources.md

Project artifact.

Sources And Provenance

External Pages Checked

• Fujara Flutes Kaval page: https://www.fujaraflutes.com/moldavian-kaval-flutes
• Fujara Flutes Alghosazi page: https://www.fujaraflutes.com/alghosazi
• Flutopedia Native American flute tunings / Anasazi note: https://www.flutopedia.com/naf_tunings.htm

Local Sources Used

• `../fujara/README.md`
• `../fujara/design-table/fujara_equations.md`
• `../fujara/CAD/fujara-body/G2Fujara_Assembly.SLDASM_dimensions.csv`
• `../drone-flutes/design.md`
• `../flutes/skills/parametric-design-table.md`
• `../pistalka/docs/build-packet/design.md`

Source-Backed Facts Used

• The kaval reference page presents fipple-style kavals and gives 5-hole and 7-hole pitch sets.
• The same page documents examples in G#, A, B, C and a double Kaval/Kavalghoza drone concept.
• The Alghosazi reference page frames the instrument as an easier fipple adaptation of an Anasazi-style flute and notes the rear thumb-hole idea.
• Tony's fujara CAD records a fipple/flue plug system with narrow windway, removable plug logic, and splitting-edge KPI values.

Assumptions Needing Prototype Data

• Exact fipple sound-window end correction.
• Final hole diameters and undercutting.
• Alghosazi mode preference after listening/playing.
• Joint effect on tuning and response.