BayTrade Churchill Fountain User manual

Instructions
Churchill Fountain Pen Kit
Tools Required
Pen Mandrel
Mandrel Saver Tailstock Live Centre (Optional)
Churchill Bushing Set
11.7mm Drill Bit
13.25mm Drill Bit
Pen Assembly Press (Optional)
Cutting and drilling the blanks
1. Cut each blank 5mm longer than the brass tube.
2. Drill a hole through the centre of the blank.
Either use a drill press with the blank secured
in a vice or clamp or use your lathe with a drill
bit mounted into the tailstock chuck.
Drill at high speed penetrating about 10 mm to
20mm at a time and then clearing the swarf to
prevent overheating of the drill bit.
To prevent cracking or chipping of the wood
when the drill bit exits the other end of the
blank, stop drilling 3mm before the drill bit reaches the end
of the blank and then trim the end of the blank using a saw
to expose the hole.
Glue the brass tubes into the blanks
1. Using 200 grit sandpaper, lightly scuff the exterior of the
brass tubes to prepare them for gluing.
2. Apply a thin layer of superglue or epoxy to the tube and
insert the tube into the blank. Rotate the tube as you push it
into the blank to spread the glue evenly –this must be done
fairly quickly to avoid getting the barrel stuck before it’s
inside the blank.
3. Position the tube inside the blank so that the wood extends
beyond the tube on both ends to allow for trimming.
Trimming the blanks
Square the ends of the wood blank with the tube using a disc
sander.
Alternatively, fasten the blank into the chuck and trim the
barrel carefully using a parting tool.

Mandrel setup and turning
1. Assemble the bushings and the blanks onto the mandrel as
shown in the diagram below.
2. Ensure that the mandrel is tight on your lathe using the
mandrel saver tailstock live centre or your live centre in the
dimpled end of the mandrel. Do not over-tighten the
tailstock or mandrel nut as this may cause the mandrel to
flex resulting in off-centre barrels.
3. An alternative is to use a mandrel saver tool to tighten the
blank into the lathe without putting strain on the mandrel
shaft.
4. Turn the blanks to the desired shape leaving the blanks
slightly larger than the bushings.
5. After turning, sand the blanks using progressively finer
sandpaper until the desired finish is reached.
General assembly points
Use a pen assembly press or vice/clamp with wood/plastic jaws
to prevent damage to the parts during assembly.
Pen assembly
Layout the parts as shown below.
1. Press the end cap into the smaller end of the long tube.
2. Remove the nib from the coupler and press the unthreaded
end of the nib coupler into the larger end of the long tube.
Fountain Pen
1. Attach the ink cartridge to the back of the fountain nib.
2. Thread the fountain nib into the nib coupler.
3. Slide the clip onto the cap, then press them into the short
tube.
4. Press the centre band coupler into the other end of the short
tube to complete the pen.
Operating the pen
1. Always keep the cap on when not in use to prevent the ink
from drying.
2. When using the pen, screw the cap over the body end