I then tune for the second / third octaves. Most people cant play more in tune than that repeatably and as I give them away to kids most will have a hard life. This eliminates variations in blowing pressure. I then put it away for at least a day and repeat the process. Then the fun bit, using a chromatic tuner I open each hole from bottom to top to within 10 cents usually with rolled up sandpaper. I then drill holes to the smallest diameter suggested by the maths. I measure out from the fipple / blowhole and skew the bottom finger hole for each hand for comfort. Once i have the numbers, I cut the fipple / blowhole and tune it, there is a book in that process, particularly for fipple flutes. What makes me giggle are the results in 3 decimal places, and as a player Im sure you will have noticed that you can easily blow a quartertone in either direction with very little effort., anyway. There are a number of them out in cyberspace and they tend to give the same answers. I usually use a spreadsheet to determine the placement of the holes. I agree with you about the challenge of tuning.
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