Phone: (888) PEN-KITS
www.WoodTurningz.com
(736-5487)
2011 WoodTurnin
z Inc.
15248
ton
reek Wa
, Noblesville, IN 46060
www.WoodTurnin
z.com
evised 1
.1
ORION PEN
Instructions
Required Accessories & Materials
• 7mm mandrel
• 4-pc. Orion bushing set (PKORIONBU)
• 25/64” and 15/32” drill bits (DB25/64) (DB15/32)
• Barrel trimmers, sizing sleeve, and/or belt sander for squaring
the tubes
• Glue (We recommend the thick “gel” CA glue—GTHICK2)
• Sanding and finishing supplies
Kit Features
• Shows off the wood in a way a smaller pen cannot
• Rollerball uses smooth-writing rollerball refill (RE-RB2)
and Fountain Pen uses cartridge refill (RE-FP10)
BLANK PREPARATION
The tubes in an Orion pen kit are of different lengths and diameter. Make
sure that, as you cut the blanks for the tubes, you orient them so that the
longer 2-3/4” tube will be used as the lower pen barrel. The upper tube
is shorter at 1-13/16” long. Cut your blanks approximately 1/16” longer
than the tube to allow for squaring with the barrel trimmer. If using wood
blanks, mark the blanks so it is easier to keep the grain running in the
same direction when you place them on the mandrel for turning. Use a
medium drill speed to drill the blanks. Raise the bit from the blank every
1/4” to 1/2” to allow the chips to clear from the flutes of the drill bit. Don’t
force the drill bit; use an even pressure and let the bit do the work. After
drilling the blanks, sand the exterior of the brass tubes to roughen their
surface and use CA glue to glue the tubes inside the blanks. Sand or bar-
rel trim to square the ends of the blanks.
TURNING THE PEN
Set up the mandrel as shown in Diagram C. The Orion pen has four bush-
ings, so proper orientation is critical. In setting up your bushings, you will
slide on one of the smaller bushings (bushing 1) first. Then slide the lower
barrel onto the mandrel followed by the other small bushing (bushing 1).
Next, place one of the larger bushings (bushing 2) on the mandrel followed
by the upper barrel and then the last large bushing (bushing 2). Keep in
mind which pen barrel you are turning as the top and bottom. Remember,
the upper tube is shorter than the lower tube. If you mistakenly get the
short tube at the bottom of the pen, the refill will not fit. Turn the blanks
down to the bushings, then sand with abrasives and finish with your
choice of polish.
Diagram A - Parts and Assembly
ROLLERBALL and FOUNTAIN PEN ASSEMBLY
(Line up finished parts according to Diagram A)
To avoid damage to components when assembling, use a vise
with covered jaws or one of WoodTurningz’ pen presses.
Assemble the four-piece upper barrel, which consists of the top cap, the
center band, clip, and short barrel. Slide the clip over the cap and press it
into the barrel. Press the center band into the bottom of the short barrel.
Final Steps for Rollerball: Slide the trim ring over the black end of the tip
(be sure the tapered end of the trim ring—the side without the lip—is facing
the tip of the pen). Carefully press the tip assembly into one end of the
long barrel. Insert the spring into the long barrel before pressing the bot-
tom cap into the other end of the long barrel (this spring is oversized and
must be inserted into the tube first; it will not push easily into the tip end
due to its size). Press the bottom cap into the other end of the long barrel.
Unscrew the plated part of the tip and then insert the ink refill; screw the tip
back on and screw the cap onto the pen.
Final Steps for Fountain Pen: Slide the trim ring over the black end of the
tip (be sure the tapered end of the trim ring—the side without the lip—is
facing the tip of the pen). Unscrew the fountain nib from the tip assembly
to avoid damage during pressing. Press the tip assembly without the nib
into the long barrel, and then press the bottom cap into the other end of the
long barrel. Press the cartridge onto the nib assembly. Screw the nib back
on and screw the cap onto the pen.
0.485”
11
2
0.532” 0.532”
0.485”
2
Diagram B - Bushings
Center Band
Spring Short/Upper Barrel
Long/Lower Barrel
Rollerball Tip
Rollerball Ink Refill
Trim Ring
Bottom
Cap
Top
Cap
2-3/4”
1-13/16”
Short Tube
(Upper Barrel)
7mm spacer
bushings
as required
Diagram C - Turning the Pen
Headstock
Locknut
Pen Blank
Long Tube
(Lower Barrel)
Cap
Bushing
Tip
Bushing
Live Center
Mandrel
Fountain Pen Nib
Fountain Pen Cartridge
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