Kaval + Alghosazi Fipple Flutes

What this is

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.

The design

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

```text 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:

```text 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.

The build

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.

No process photos in images/. Add at least one to populate this section.

The numbers

BOM

Cut list

Tuning & validation

Known risks

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.

Family overview

• KAV-GS3-5H — G#3
• KAV-A3-5H — A3
• KAV-B3-5H — B3
• KAV-C4-5H — C4
• KAV-A3-7H — A3
• KAV-AS3-7H — A#3
• KAV-B3-7H — B3
• ALG-AS3-J2 — A#3
• ALG-AS3-SOLID — A#3
• ALG-A3-J3 — A3
• ALG-B3-SOLID — B3

Resources

• Project README
• Capstone deck (.pptx)
• Printable shop packet (.pdf)
• Tony's GitHub