KIT FEATURES
• Heavy 24kt gold plating
• Oversized (Almost 6 inches in length)
Step1 - Cut Wood Blanks
- From 5/8" to 3/4" square stock, cut blanks to the length
of the tube plus 1/8". Grain should run lengthwise. To maintain
the grain pattern continuously over the length of the entire pen, cut
one blank long enough to make both parts plus waste. Mark both ends
to indicate top and bottom prior to cutting them apart. These blanks
must remain identified throughout the process to make shure they are
assembled together.
Step 2 - Drill the Wood Blanks
Drill a centered hole lengthwise through each blank. You may use our drill
guide or any other device to help ensure a straight hole. Excessive pressure
may cause the drill bit to wander and/or split the blank if not held firmly.
Slow the feed rate and back the bit out repeatedly for chip removal: For
best results - use a 10 mm drill bit (10mm=.3937 dla.). If not avaIlable,
use a 25/64" (.3906 dia.) bit - although slightly smaller than the
10 mm bit, you will get acceptabie results.
Step 3 - Glue the tubes into the blanks
Use epoxy or a gap filling cyanoacrylate (super glue), glue the
tube into the blank. Coat the outside of the tube, then insert into the
blank with a twisting motion to spread the glue until flush. Allow it
to dry.
Step 4 - Square the ends
With a barrel trimmer, disc or other sanding device, square the
ends of the blanks 90 degrees to the ends of the brass tubes as needed.
Step 5 - Turn the wood blank
Install the blank on a turning mandrel with a bushing
against each end. Tighten the nut snugly and bring the tailstock center
firmly against the end of the mandrel. Tum or file the diameter down to
slightly larger than the bushings (about 15/32"). As you approach
the final size, flush with the bushings, be careful since the wood is
only about 1/32" thick. |
6 - Sand
As with any sanding, progress through a range of grits. The type of
wood used and the quality of the beginning surface will dictate your
selection.
- 80-100 grit if rough surface or additional shaping is needed (overly
thick)
- 120-150 grit if fairly smooth and straight
- 220-240 gnt for final finish with most domestic woods
- 320-400 grit cspecially on dense or oily exotic woods
Scotch brite works well and doesn't tend to scratch. Sand with blank
spinning. For initial shaping, stick
sandpaper on a board wide enough to remove any hills or valleys.. The
center ring is 29/64" in dia. Do your final sanding with the grain
and the lathe off. The final size for a good fit is between 27/64"
and 29/64".
Step 7 - Finish
Try a finish of your choice but be careful if brushing on a poly,
etc., you could stick the tube, bushings, and mandrel together. The following
friction polish works well on most woods.
1/3 wood alcohol (methanol, 1/3 white/clear shellac, 1/3 boiled linseed
oil.
Mix equal parts of the three ingredients in a bottle and shake before
using. Apply with a rag to the spinning tube. Apply two coats. Remove
the tube from the mandrel.
Step 8 - Touch up
With tubes off mandrel, lay them end to end to decide which sets will
look best when assembled. Remember, they will be .10" apart (due
to center ring) so minor differences won't show. If necessary, a light
sanding of the tube ends on a block will square them and improve the fit
during assembly.
Step 9 - Notch sleeve
Cut out a small notch in the wooden blank to match the notch in the brass
sleeve. This is best accomplished by using the edge of a single cut mill
file.
Fabrication aids
Drill bits, drill guides, and mandrels are available - check our catalog.
|
| a) Line up cap. longer sleeve and threaded coupling. Make
sure that the longer shoulder of the coupling is inserted in the sleeve.
b) Press components (above) together gently with your vice.
c) Screw tip into coupling.
d) Line up cap/clip unit with shorter sleeve making sure that the clip
is aligned with the notch in the wood.
e) Slide the plastic pen top retainer inside the top sleeve closed end
first. Use a 5/16 phillips head screw driver inserted into the top sleeve
to screw on the pen top retainer.
f) Adjust closing mechanism for a tight fit by inserting screw driver
and turning clockwise.
g) Insert ink cartridge. A spare cartridge may be stored in the pen
barrel placed back to back with the existing cartridge. |
a) Line up cap. longer sleeve and threaded coupling. Make
sure that the longer shoulder of the coupling is inserted in the sleeve.
b) Press components (above) together gently with your vice.
c) Insert spring, flat end first into sleeve. Insert rolier ball refill
blunt end towards spring. Screw tip into coupling.
d) Line up cap/clip unit with shorter sleeve making sure that the clip
is aligned with the notch in the wood.
e) Slide the plastic pen top retainer inside the top sleeve closed end
first. Use a 5/16 phillips head screw driver inserted into the top sleeve
to screw on the pen top retainer.
f) Adjust closing mechanism for a tight fit by inserting the the screw
driver and tuming clockwise. |
