At Allen Creek Farm there's not much that isn't recycled.  The first year that we lost trees we cut them up for firewood.  After that we decided there just had to be a better use of this wood that we were discovering was beautiful and truly unique.  And so the woodturning began.  At first it was only bowls and we still do them, but then we began doing duck calls.  We're just a mile from the Ridgefield National Wildlife Refuge and ducks and geese visit us daily during the Fall and Winter months so duck calls seemed a natural.  Our duck calls will be available about Oct. 1, 2011.

When a tree is cut down, it's cut into logs for handling.  Here a log is being split down the middle with a chain saw.
 

The split log is cut down on the band saw to get it to a size that can be handled on the circular saw.

The wood is now of a size that can be handled on the circular saw.  It's started through by hand then finished with a push stick for safety.

The block of wood is first drilled and then placed on the mandrel where it will be worked. 

The first step is getting it round and I begin with a roughing gouge.

At last it's round.  Once I get it to the proper diameter I'll start the pattern.

I use a digital caliper to make sure the diameter is correct.

Next, we mark the location for the first cut which will allow us to install the brass band.

Now I've marked lines to locate the edges of each indent or edge and I'm beginning to cut the insert for the band.

Next, it's time to cut the grooves for each of the indents.

After cutting the beads and inset for the lanyard I work on shaping the  rest of the call.

Now it's time to sand.  I go over it with 450 grit paper and then 600 grit until it's ready to finish.

I use a friction finish.  It's much easier and faster than lacquer and leaves a glass-like finish.

A soft paper towel is placed over the call while it's spinning on the lathe creating the heat required to set the finish.

The brass band is glued in place.  The band is decorative but also serves to eliminate possible splits in the wood.

I finish sanding the area above the band, apply finish and the tone channel is complete.