# Ocarina Assembly Manual

## Scope

This manual covers a slip-cast or press-molded ceramic ocarina based on `docs/Ocarina.xlsx`. It is written for prototype builds where the first goal is repeatable tone and validated tuning, not decorative finish.

## Tools

- CAD package for master design.
- 3D printer and sanding/sealing supplies.
- Cottle boards, plaster mixing bucket, scale, mold soap, and clamps.
- Stoneware slip or workable clay body.
- Small hole cutters, drill bits, needle tools, loop tools, ribs, sponge, and fettling knife.
- Chromatic tuner, microphone, calipers, graduated syringe or water-fill vessel.
- Diamond needle files or fine diamond burrs.
- Wax resist, glaze, and kiln access.

## Process

1. **Set design inputs**
   - Confirm target ocarina size, chamber volume, voicing window, wall thickness, clay body, and shrinkage.
   - Create a build ID before CAD begins.

2. **Model the master**
   - Model the body as a controlled-volume vessel.
   - Include split-line planning, registration features, and a fipple strategy.
   - Scale the master by `1/(1 - measured_shrinkage)`.

3. **Print and finish the master**
   - Print the master with enough wall strength to survive mold making.
   - Sand layer lines and seal the surface.
   - Mark datums: centerline, mouthpiece axis, split plane, and hole reference side.

4. **Make the mold**
   - Apply release to the sealed master and cottle surfaces.
   - Pour plaster with at least 1.5 inches around the master where practical.
   - Add registration keys and dry the mold fully before casting.

5. **Cast or press the body**
   - For slip casting, pour slip, wait for target wall buildup, drain, and demold at leather-hard stage.
   - For press molding, press even clay slabs into both mold halves and join with scored slip.
   - Measure sample wall thickness at a noncritical trimmed area.

6. **Cut fipple and holes**
   - Establish the windway first.
   - Cut the labium cleanly and test blow before the body fully dries.
   - Cut finger holes undersized.

7. **Dry slowly**
   - Dry under plastic until moisture equalizes.
   - Watch the mouthpiece and seam areas for cracks.

8. **Bisque fire**
   - Bisque to the clay body's recommended schedule.
   - Measure mass, volume, hole diameters, and frequencies.

9. **Tune after bisque**
   - Enlarge holes to raise pitch.
   - Refine the fipple only in small steps.
   - Record measured frequency and cents error after each change.

10. **Glaze**
    - Wax resist the windway, labium, holes, and any interior opening.
    - Keep glaze away from the acoustic edges.

11. **Final fire and validation**
    - Fire to the chosen glaze schedule.
    - Re-measure all tuning points.
    - Save final dimensions and tuning data back into the validation log.

## Failure Modes To Watch

- Weak or no tone: windway too tall, labium too blunt, air jet missing edge.
- Pitch too flat: chamber too large, open area too small, or neck length too long.
- Pitch too sharp: chamber too small, open area too large, or over-filed holes.
- Warped mouthpiece: uneven drying or thin unsupported fipple geometry.
- Glaze-choked note: glaze reduced hole or windway opening.