The Perils of Detail

My cub scout son suggested before last week's weekend camping trip that we all get whistles in case of emergencies. a while back i figured out which 3D printed whistle was best so I whipped out the STL and printed a few more copies.

A number of things has changed on my side since my last printing, most notable of which is the slicer. Joe Sadusk informed me a while back that the MakerWare slicer fixes a problem previous slicers have with thin spaces. MakerWare actually identifies areas too small for a standard wall and fills it with a single wall, allowing for better details and more complete layers. However in the case of the whistle the labium gets a little extension that the old ones didn't have. As a result it doesn't make any sound until that fragile bit is cracked off. Unintended consequences. But is the problem with the slicer or the model being made for an inferior slicing algorithm? Things that make you go "hmmm". Personally I'm not willing to give up the detail I've gained to have the old whistle model work. I just need to find a new whistle model, I guess.