1. Select the Material:
Choose a suitable metal for the flute. Common metals used for flutes include silver, gold, platinum, and certain alloys.
2. Prepare the Metal:
- Cut the metal into a flat sheet.
- Anneal the metal to make it easier to work with.
3. Shape the Headjoint:
- Cut the headjoint blank from the sheet metal.
- Shape the headjoint using specialized tools to create the desired shape and embouchure hole.
4. Form the Body and Footjoint:
- Cut and shape the body and footjoint sections.
- Roll the metal sheet to create cylindrical sections.
- Join the body and footjoint sections by soldering or brazing.
5. Add Tone Holes:
- Mark the locations for the tone holes on the body and footjoint.
- Drill holes at the marked locations.
- Deburr and smooth the edges of the tone holes.
6. Shape and Solder the Keys:
- Cut key blanks from metal sheets.
- Shape the keys and attach them to the flute body with posts and screws.
- Solder the keys in place.
7. Adjust the Keys and Mechanism:
- Regulate the key heights and alignments to ensure proper playability.
- Install springs and adjust the key action.
8. Finishing:
- Sand and polish the flute to a desired finish.
- Apply a protective lacquer or coating to preserve the metal.
Remember, making a metal flute requires specialized tools, knowledge, and experience in metalworking. It's advisable to learn the craft under the guidance of an experienced flute maker or through specialized courses or workshops.