My Method - Pot Calls

JR Custom Calls

JR Custom Calls

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Winchester, Ky
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Jonathan
Everyone has their own way of doing things. This is the way I have adopted. I had a few orders come in last night, so I figured I'd spend a minute or two extra taking some pics along the way.

Crosscut hedge seems to have piqued the interest of several customers. Normally, burnt hedge is a favorite... and even though a few extra steps, a bit easier.

When I'm doing a batch of calls, I do each process for all of the calls before moving on to the next step. Saves time and keeps me in the groove. Total time per call is about 5-10 minutes.

I start with a 1x4x4

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1374_zps1caf7e90.jpg

I draw a line from corner to corner and drill a 3/4" hole

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1375_zpsd12753b2.jpg

I chuck the blank and use the corner of my square cutter to scribe a line as it spins to form a circle (while the lathe is on)

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1376_zps4196b7b1.jpg

I follow the line as best I can on the bandsaw, making it *almost* round

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1377_zps2107578d.jpg
 
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I chuck it back up, and true up the blank on the face. Then I use a pen or pencil and mark around a 3.5" glass, centering it as best I can by eye.

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1378_zpsa312438d.jpg

I begin removing wood inside the line, estimating approximately how far down to go to get the glass level with the pot. It doesn't have to be perfect, as it's simple to go back and remove more, or since the blank is still close to an inch, remove a little from the edge. Once it fits properly, I trace a 3" glass inside of that, and start removing wood. Eventually, I need to get down to where I can stick two pieces of 3" glass in and it be about flush with the bottom of the ledge I just created for the 3.5" surface.

Once I get the soundboard height right, I start removing more wood, this time leaving about a 1/4" pedestal for the soundboard to rest on. I go down 3/8" (eyeballing by the size of my square cutter), from the pedestal over to the side of the pot.


http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1379_zps92efcc6f.jpg

Once the inside of the pot is done, I use a template that I printed off, then customized a bit, to punch a mark with a nail where I'm going to drill my sound holes.

Using a 5/16" forstner bit, I drill the sound holes. On plain sawn wood, there's usually a bit of tear out inside.. that's no problem, just clean it up with a razor blade afterwards. On crosscut, it usually just plows right through and leaves a clean hole.

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1381_zps57e5afa2.jpg

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1382_zpsd415928c.jpg
 
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Now I chuck the blank up with the bottom out, get it round, and set my height. Again, I do this by eye, based on the distance to the jaws.

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1384_zpsfbf22bc3.jpg

Once my height is set, I begin shaping the call

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1385_zps653536a0.jpg

Once it's shaped, I hit it real quick with some 320 grit, then buff with steel wool

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1386_zpse8558228.jpg

On the crosscut, the holes get a little messy while turning. I just go back to the drill press and clean up the holes

Now we're ready for sanding the holes, a finish (tru oil), and to glue up the sound board and playing surface

http://i1024.Rule #2/albums/y306/jrcustomcalls/IMG_1387_zpsd1cabebe.jpg


I hope this helps someone who's wanting to get in to turning pots, or looking for a new way to try it. Some may think that I'm being lazy by not measuring... but the way I see it, I sell *Custom* calls, and every one of mine is unique from the next... but sound equally as good.
 
Jonathan - excellent series. If you have them and don't mind post all the way through the finish. As a collective bunch I find that call makers are probably he best lot of finishers out there.
 
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NYWoodturner said:
Jonathan - excellent series. If you have them and don't mind post all the way through the finish. As a collective bunch I find that call makers are probably he best lot of finishers out there.
Click to expand...

I'm not the best finisher by any means... I'd say that's my biggest weakness. But I'll add in a few pics of the tru oil finish.

elijahhenry10 said:
Awesome write up. I wonder what burnt crosscut hedge would look like. If possible at least.
Click to expand...

Ask and ye shall recieve. I'll give it a go tomorrow if I can get out in the shop.
 
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@elijahhenry10 didn't turn out as I expected. Lots of checking, which I was sort of expecting. That said, I'm curious about the long term effects of this shallow checking because I think it looks really cool... Kind of that weathered, rustic look.

image.webp
 
Great tutorial Jonathan. Show how you sanded those holes. It's a pet peeve of mine to see new call makers not bother to do it, and surprisingly I see some experienced call makers ignore them. That's like leaving pencil or scribe lines on the corner of a dovetailed piece - just crawls all over me.

How did you center your glass template over the call? Do you use a pencil while it spinning to scribe a couple of circels and just center the glass over the one you guesstimated closest to 3.5"?
 
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Kevin said:
Great tutorial Jonathan. Show how you sanded those holes. It's a pet peeve of mine to see new call makers not bother to do it, and surprisingly I see some experienced call makers ignore them. That's like leaving pencil or scribe lines on the corner of a dovetailed piece - just crawls all over me.

How did you center your glass template over the call? Do you use a pencil while it spinning to scribe a couple of circels and just center the glass over the one you guesstimated closest to 3.5"?
Click to expand...

You're the reason I pay attention to holes... Haha. All I do is go back and run the bit through them again once I get done turning. The forstner bit leaves a smooth surface inside. I use a q-tip to apply finish inside them. I do just was up some 320 and sand the edges of the big hole.

As far as centering the glass, I just hold it up to the blank and eyeball it, then trace it. As I'm turning, I get close to the line, stop and check fitment, then keep going. Since there needs to be a slight gap around the edge, it doesn't have to be exact... Just needs to fit loosely. I know it's not the most precise way, but I can't justify taking the time to use calipers or any of that stuff for something that doesn't have to be consistent within .001"
 
JR Custom Calls said:
@elijahhenry10 didn't turn out as I expected. Lots of checking, which I was sort of expecting. That said, I'm curious about the long term effects of this shallow checking because I think it looks really cool... Kind of that weathered, rustic look.

View attachment 59629
Click to expand...
It does give it a neat look. I wonder if a CA finish would help hold it together. It'd be worth a shot at least I think. Either way it looks good.
 
Great job, Jonathan. These tutorials give me ideas on things to do during the boring winter months.
 
Very good job on the pot, as well as the tutorial. Have you ever given "Call-Coat" a try? I like it for a finish
as well as Velvit oil. The holes I usually just run a dremel barrel sander thru gently, seems to work well.
 
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eaglea1 said:
Have you ever given "Call-Coat" a try
Click to expand...
I haven't... But I have read up a bit on it. I have been thinking about it more and more lately, as I've been expirementing with some new finishes. Looks like it gives a pretty decent shine, I just wonder how big of a pain it is to use.
 
Great thread - I don't know if I am the only one but a few pics of how it is used would be helpful. Until I joined I had never heard of a pot call.
How does it work? I assume it is for calling to something to get closer to you?
As you can see I am not much of a woodsman, although I have spent time under canvas with the Boy Scouts as a youth and leader.
Thanks
John
 
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Johnturner said:
Great thread - I don't know if I am the only one but a few pics of how it is used would be helpful. Until I joined I had never heard of a pot call.
How does it work? I assume it is for calling to something to get closer to you?
As you can see I am not much of a woodsman, although I have spent time under canvas with the Boy Scouts as a youth and leader.
Thanks
John
Click to expand...
I'll see if I can get a video this weekend. For the time being, here's one I found on youtube.

 
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I decided to make a quick video as I was making a few tonight. The part where I cut the corners and round it off got left out, as my phone fell off my makeshift tripod (aka, it was sitting on a shelf with a call blank holding it up and fell off halfway through). So, I figured I'd upload the more important one. This is the making of the inside and the final dimensions of the outside. I've still got to drill the sound holes and do a quick buff with steel wool before putting a finish on it, but it should give a better visual of how I go about doing it. As you can see, it takes just a few minutes, and that was with me fumbling around because I knew I'd post this on here.

Don't get me wrong with this tutorial, this is not something you can just expect to perfect on your first one. It has taken me quite a while to get to the point where I can get pretty much dead on without going back and measuring everything. Oh, and shoutout to @woodtickgreg , the square cutter in the video came from him. These carbide tools are the bomb.

 
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