For those of you who are constantly researching tech type information (Micron and Jbutkey)do you have any sites to recommend where you can actually see the process of a metal flute being made?

As I was falling asleep last night I was thinking about how artistically beautful John Lunn Flutes are. (He is no longer making new ones ). For some reason that had me start thinking about how flutes are actually made. Here were some specific questions that popped in to my head:

1. You can't see any solder lines on the body where the metal was rolled. I am curious to see this process and the process where the holes for the keys are either cut in or soldered on.

2. There are tons of pins and mechanism parts. When a flute says Handmade, are these parts handmade?

I guess I am mostly curious about the actual metal working involved. If you know of any sites to recommend I would appreciate it! I have looked on a few sites and I can only find pictures of techs huddled over a flute.

Probably the best way to learn about these types of things is to visit a flute workshop and actually see some of the work being done. I'm not Micron or Joe, but I think I can still answer your questions for you.

1: In the past, flutes were made with a seamed tube. This is where a flat piece of metal is rolled into a tube, and soldered. Today, most flutes are not made with seamed tube (Altus, as well as some smaller makers do still offer seamed tubing as an option), but rather start with tube that has been drawn from a flat disk of metal, which means that no seams should be visible. For drawn toneholes, a small hole is made in the tube where the tonehole will be, and a small ball is placed below it. This ball is then pulled out, creating a tonehole, and the top of the tone hole is rolled over to create a smooth surface for the pad to seal on. Soldered toneholes are made independently from the flute, soldered on where the maker wants a tonehole, and then a hole is drilled through the tube in the center of the tonehole. One website that you might find interesting is http://www.yamaha.co.jp/edu/english/factory/fl/fl_001.html It describes and illustrates some of the steps involved in building a flute, and includes some photos.

2. There are varying levels of handmade-ness, and no definitive amount of the flute must be handcrafted for the maker to call it handmade. In the very best flutes, all the parts are made specifically for one instrument, by hand, but some instruments are also called handmade that have only part of the flute actually made by hand.

Hope that's helpful!

if you are ever in Boston, many of the companies there will give you a guided tour, I was given a tour of the Haynes factory by the late great Lew Deveau and I still remember that day

Thank you guys for the info! You just gave me something to look at when I am bored at work! I appreciate it.