| Making custom pens is a very enjoyable hobby. Many | | | | Special clamping vises are available for drilling the |
| woodworkers do nothing else, as this is an easy way | | | | center hole and are very handy. They make drilling |
| to make a project from start to finish in very little | | | | the hole perfectly parallel, much simpler. Although |
| time. It doesn't require a large investment in tools and | | | | they are around $30.00, they are well worth it. |
| materials, or require a large work space. | | | | Another way to drill the blank is to hold it in a wood |
| Required Tools (the very basics) | | | | clamp, making certain it is square to the table. Doing |
| 1. A small lathe, used to turn the pen. | | | | this is a bit tricky, and a little aggravating, but |
| 2. A single turning tool, like a medium sized gouge to | | | | certainly doable. |
| shape the pen. | | | | Once the drilling is completed, gluing the brass tube is |
| 3. A small drill press, which is optional, to drill the | | | | next. Again, there is a tool designed for this, (around |
| center hole. | | | | $ 10.00), but a nail set works just fine. Using super |
| 4. A mandrel, which is the tool the pen blanks are | | | | glue works well, as does epoxy. The thick, gap filling |
| mounted on, and installed on the lathe, and have | | | | super glue is the one to use. Before applying the glue, |
| bushings, which guide you in turning the ends to the | | | | sand the tube a little, just to rough it up and give the |
| desired diameter. | | | | glue something to "bite" on to. Apply the glue around |
| 5. A method of pressing the pen hardware together | | | | the tube and insert it into the hole. Depending upon |
| is really all you need to go from a square pen blank, | | | | the cure time of the glue, leave it until the glue is dry. |
| to a beautiful, finished pen blank. Many people use a | | | | Again, there is another tool, ($15.00), designed to |
| wood clamp for this. | | | | clean the excess glue from inside the tube, as well as |
| Required Materials | | | | drill the end of the blank flush to the brass tube. |
| 1. Pen blanks, as they are called, is a small piece of | | | | Another way is to sand the blank ends flush. If any |
| material, usually ¾ of an inch square, by 5 | | | | glue resides in the tube, insert a small drill bit, |
| ½ inches long, are readily available from many | | | | matching the tube size, and drill it out. |
| sources. | | | | Now it's time to mount the two pieces onto the |
| 2. Pen Kits, also available at these same supply | | | | mandrel, surrounded by the included bushings. The |
| sources, contain all the actual pen parts. | | | | bushings are the proper size to turn the blank flush |
| 3. Epoxy, or super glue, is used to glue the brass | | | | to, and are sized according to the pen kit. The |
| tube into the pen blank. (The brass tube is supplied in | | | | mandrel is held in the lathe on both ends by the |
| the pen kit). | | | | chuck on one end, and the tailstock on the other. It's |
| 4. A finish to put on the pen to protect it from the | | | | important to use a live center on the tail stock. This |
| oils on your hand during use. | | | | simply means the pointed tip spins freely, apart from |
| The blanks can also be purchased with much of the | | | | the center itself, especially with acrylics, otherwise, |
| work, if it can be called that, pre done. They are | | | | the end will overheat. The acrylic blank will actually |
| already cut to rough length, and rounded to an | | | | start to melt. |
| appropriate size to begin turning. The required hole is | | | | Using the turning tool you choose, a gouge is |
| also drilled to accept the pen hardware, eliminating | | | | recommended, turn the blank to the desired shape. |
| the need for a drill press. | | | | Here it is a matter of practice, in learning the control |
| These blanks come in many materials. Exotic woods, | | | | of the tool, and the techniques used for turning. It is |
| certain metals, plastics, solid surface materials, like | | | | advisable to practice on a cheaper blank, at least until |
| Corian, and much more. Even deer antlers are a | | | | you are comfortable with turning. It's really irritating |
| commonly used material, and are easily obtained. | | | | to ruin a beautiful pen blank! |
| The Pen Kits, which is how the hardware of the pen | | | | Once the blank is turned to the desired shape, and |
| is purchased, are available in many styles and finishes, | | | | you're happy with it, it's time to finish it. The finishing |
| and include all the necessary parts to complete your | | | | process is very easy, and very satisfying. It's when |
| pen. Specialty pens, created around other hobbies, | | | | you get to see the fruits of your labor. Depending on |
| such as hunting, or fishing, and sports like baseball or | | | | the blank material, the finishing process is done with a |
| football, hockey or tennis, pretty much anything you | | | | variety of products, but in every case, is done while |
| can think of, have pocket clips customized to allow | | | | still mounted on the lathe. |
| you to make the pen for anyone. Even clips for | | | | When the pen blank is removed from the lathe, it is |
| different professions like doctors or lawyers are | | | | completely finished. Once more, a special tool can be |
| available. | | | | used to assemble the pen. (About $ 30.00). This is a |
| Procedure | | | | press, designed specifically to push the pen parts |
| If buying the standard sized pen blanks, the first step | | | | together, ensuring the parts fit properly. It can be |
| is to cross cut them in half. If making several at a | | | | done with a wood clamp, but the press is a much |
| time, laying them against a fixed object, and with the | | | | better way to go. |
| ends flush, mark the halfway point on one blank and | | | | The entire process of making a pen can be done in |
| using a square, mark all the blanks. The safest way | | | | less than an hour, and is a great way to enjoy |
| to cut them is a band saw, if available, but even a | | | | yourself, and forget the hurries and worries of the |
| hand saw is fine. | | | | world. |
| If you intend to mass produce them, it's worth | | | | They can also be sold to generate an extra income, |
| making a jig to eliminate the measuring and marking | | | | or given as gifts which will be very much appreciated. |
| step. It is then just laying the blanks on the jig and | | | | The user will think of you every time they write |
| cutting them with an appropriate saw. | | | | something. It's the perfect gift that keeps on giving. |
| The next step is drilling the center hole, lengthwise | | | | Overall, this is a terrific hobby, is very safe, even for |
| through the blanks. The hole size is determined by | | | | youngsters, with adult supervision, and will lead to |
| the type of pen kit used, and is noted in the kit. | | | | many hours of fun. |
| 7mm is very common. | | | | |