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