PROJECT PEN KITS
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WHAT’S REQUIRED
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Preparing a wooden or acrylic/polyester
blank for a pen mandrel.
1. Cut a blank to the length of each tube
plus approximately 2.5mm to allow for
trimming and squaring off the ends.
2. Mark the centre on the end of the blank.
3. Using the recommended drill bit, drill a
hole lengthwise through the blank.
4. Apply epoxy glue, Polyurethane glue or
gap filling cyanoacrylate (super glue) to
the tubes.
5. Insert the tube into the blank with a
twisting motion to spread the glue
evenly inside the hole.
1. Mount the bushings and blanks onto a
pen mandrel according to the diagram
(If using a wooden blank, check the
grain alignment).
2. Secure the bushings and blanks onto
the mandrel.
3. Slide the tailstock with a live centre into
place against the mandrel and lock in
position. This is for support; only slight
pressure is required.
Bushing Set:
104367
Drill Bit Size:
8.7 mm (11/32”)
Minimum Blank Size:
16 mm x 16 mm x 88mm
6. Centre the tube lengthwise inside
the blank.
7. Allow the adhesive to cure.
8. When cured, square the ends of the
blank. Using a barrel trimmer with a
guide matching the inner diameter
of the tube or a universal pen blank
squaring jig with a disc sander.
9. Take the excess material down flush
with the ends of the brass tube. (do
not trim beyond the length of the tube
since this may interfere with operation
of the mechanism and assembly).
Tips/Hints
•If using a wooden blank, draw a short
pencil line lengthwise across the
centre of the blank. This will help
maintain grain alignment when
mounting the blanks onto a mandrel.
•Excessive pressure may cause the drill
bit to wander and/or split the blank.
Slow the feed rate and back the drill
bit out repeatedly for chip removal.
•Roughen the brass tube slightly with
abrasive for better adhesion.
•Certain acrylic blanks are more
transparent than others, especially
lighter colors or blanks with light
colored swirls. To avoid the risk of
the brass tube showing through the
pen blank, paint the tubes white or
black before gluing them in.
•The barrel trimmer guide also cleans
any adhesive that may have gotten
inside of the tube.
4. Using sharp tools, turn the blanks down
to become the Pen Barrel and the Cap
with the profile of your choice.
5. Turn the blanks very slightly oversize,
then sand and polish the ends down to
the same diameter as the bushings.
6. Using successively finer abrasives
gradually sand and polish the Pen
Barrel and Cap.
7. Finish the Pen Barrel and Cap with your
preferred choice of polish.
Tips/Hints
•Don’t be afraid to sharpen frequently
especially when turning acrylics.
Tooling Stylus Tip Ballpoint Pen Kit - Chrome
Code: 104356
PREPARING THE BLANKS, HINTS & TIPS
TURNING THE BLANK, HINTS & TIPS
