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How To Make A Train Whistle Out Of A Scrap 2x4

 In this weeks edition of BS with AJ I show you how to turn a scrap piece of 2x4 into a cool train whistle that you or your kids can have plenty of fun with. first cut down your piece of 2x4 to 6 1/2" on a miter saw. then you want to rip it on a table saw to 1 7/16". next you need to cut 5/8" off which ever end you decided to be the top and set it aside. then you need draw a line from each corner to separate it into 4 equal spaces on the top . next you take a square and mark 3/8" from the edge to intersect the marks you made previously. you take an awl and put a press it into the places the marks intersect to make a small hole for your 1/2" brad point drill bit to line up with. I made a jig to accomplish this, I lined it up for one side and just turned the block for each hole I needed to drill. here are the depths for the holes to drill.
1st hole: 2 7/8"
2nd hole: 3 5/8"
3rd hole: 4 3/8"
4th hole 5 1/4"

after you have drilled the holes you need to mark a line at 5/8 inch down from the top all the way around the block, then mark another line 3/4 down from the first line. then draw a 45 degree line from the edges of the bottom line to the center of the top line on all 4 sides. I cut a piece of 2x/4 at a 45 degree angel to set my block on to cut the lines out with my scroll saw. cut them out as shown in the video. after your finished cut 4 pieces of 1/2" dowel a few inches long and sand one side flat, place each piece into the holes you drilled until it reaches the top of the hole you cut out of the side. test each of these to be sure they all make a whistling noise. next glue them into place and let dry. take the top piece you set aside and drill 1 1/4" hole about 1/3 of the way through, then drill a 1/2" hole the rest of the way. when the glue has dried cut off dowels flush and glue on the top piece. sand it down smooth and test it out.

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