Dear Dennis, I came across your "How to make a Penny Whistle in a Few Days" posting on the net. It was great and I thank you for it. I tried two types of materials - aluminum - ID.94 with.029 wall thickness, copper - ID.811" with .032 walls. They both gave me a problem in that my hands arent very big and the finger stretch, especially between holes 5 and 6 was just too much. I have a Chieftain and after measuring it - ID.862" with .073 walls, I decided that maybe it was the wall thickness that was creating the large spread in the holes. So I searched for and found some aluminum pipe (actually it is fairly hard so is probably an alloy) that has an OD of 1", ID of.884" and wall of.058". It worked! The finger spread is greatly reduced. The identifying numbers on the pipe are: Alcoa P USA 245498-1-1 6061 - T6 WW-T-700/6f-2 AMS 408DM ASTM B210-95 SEAMLESS 1.000DX.058WALL. The figures on the hole placement and diameter, etc are as follows. (Sorry about mixing mm and inches. It is my measuring tools.) Hole Diameter Dist. From lip to hole center 1 .375" 247mm 2 .375" 282mm 3 .345" 320mm 4 .285" 370.5mm 5 . 470" 407mm 6 .360 449mm Air way length = 34mm Air way height = .045" Window width = 15mm Window depth = 12mm Lip to open end = 538mm End to end = 580mm. A trick I used for making the fipple end flat on top and the indentation down wind of the window was to shape a wooden dowel with the two flat are a on the top, place it in the tube and then press it down with a vice and a bit of hammering by hitting a flat piece of iron placed on the tube in the right area and hitting it with a hammer. The other thing I have found good was to get a 1" Plexiglas (Lucite) rod and shape it for the plug. It files and cuts fairly easily and there is no problem with it expanding when it get wet. Also, taking and idea from the Chieftain, I beveled the end of the block at 45 degrees along the top edge that sets just below the up wind side of the window. It seem to give it a bit better tone and volume. That is every thing I can think of that I did. I hope it will be useful to you, and if you want to add it to your web page, it is fine with me. Thanks again for teaching me how to go about it. Regards, Bob Dr. Bob Willihnganz B.C., Canada