Ok, Here is a rundown on the call making.
Here you see Mr. Jordan at the lathe. He has automated this lathe to the point all he has to do is center the wood, pull a lever, and flip a switch. On the lathe now is the tone board profile. If you'll look, hanging on the shelf to the right, is a profile for the call barrel.

You can see the metal profile in the lathe here.

He has all his automations run with cut off or limit switches. So when they run their length, they automatically cut off.

The tone boards would then move over here to be cut.
Note, this is a mounted and modified Skil saw. Place the raw tone board in the hole on top, and run it over the saw blade.


Next he would precisely cut the scrap piece off the tone board by placing it in the jig on the left of this next piece of equipment.

This piece also makes his tone board arch. It is a everyday router, mounted on a slide with a jig to guide the cutting blade. He says that when the tone board comes off here, it is 90% tuned.


Then comes the cutting of the reed. He uses .10mm Mylar. Places in another, you guessed it, jig.
At bottom you see the jig to shape the reed.
In the middle, once the reed it shaped, it is cut to length and notched on a corner to assure correct orientation.
At top, this piece shapes the edge of the reed after it is cut.

Setting the jig to shape the reed.

Then just cut with a pocket knife.

Now, cleaning up the edges of the reed,




Cut to length

We sat down and chatted for a good hour after he showed me his process. Great guy.