In this Instructable, I challenged myself to making a pen without a lathe or a drill press. But, let me be honest, I just don’t have those tools. The slim-line pen kits came from Rockler and they were on sale over the holiday season. The wood that was used is Cocobolo.
Step 1: Measuring and Cutting Pen Blank
Here I am measuring out the blank to be cut in half. One line is the halfway mark while the other is for alignment purposes.
Step 2: Drilling Channel for the Pen Cylinder
Here I'm using a jig to make a straighter hole for the pen cylinder.
Step 3: Cutting Off Some Excess
Here I'm cutting off some excess pen blank.
Step 4: Scuffing Up the Pen Cylinder
Use some 120 grit sandpaper to scuff up the pen cylinder.
Step 5: Glueing in the Pen Cylinder
Use CA Glue (super glue) to bond the pen cylinder into place.
Step 6: Sanding to Make Pen Blank Flush
Use the belt sander with 120 grit to make the pen blanks flush.
Step 7: Cleaning Out the Cylinders
Step 8: Mandrel and Alignment
In this step, align the blanks on the mandrel. Use the center line that was drawn on the pen blank to align where the blank was cut. This will insure the correct grain pattern.
Step 9: Belt Sanding to Rough Out Shape
Here, I'm using 120 grit sandpaper to rough out the shape of the pen.
In this step, use the backboard on the beltsander it will assist with cutting away the material faster.
Advice - take your time and leave plenty of material and avoid the bushing on the mandrel.
Step 10: Belt-Sanding to Finalize the Shape
Here, I'm using 400 grit sandpaper to create the final shape of the pen.
In this step, the sandpaper is being used without the backboard on the beltsander. This allows for the material to be slowly taken away and gives more control to the worker.
Step 11: Hand-Sanding
In this step, serveral grits of sandpaper is being used to create a glass-like finish. The sandpaper is cut into small strips approximately 1x4 inches.
Grits - 220 - 320 - 400 - 800 - 1500 - and 2000
Advice: I like using the gloves because the sanding causes a great deal of friction and will begin to burn fingers.
Step 12: Finishing
I'm just using a paste wax for the finish. Give an ample amout of wax and let sit for about twenty minutes. After letting the wax settle into the wood, clean any excess off with a rag.
Step 13: Stage One of Pen Assembly
I take the time to lay out the pen materials in their order:
First: press in the nib
Step 14: Stage Two of Pen Assembly
Second: Press in the twist mechanism.
Advice: go slow when pressing in the twist mechanism as you don't want to press it in too deep.
Test the fitting by twisting to full extension and the full closed position.
Step 15: Stage Three of Pen Assembly
Press in the cap and clip
Step 16: Final Stage of Pen Assembly
Slip on center gold ring and slide on pen cap.
Step 17: The Beautiful Pen Completed
I actually made a few pens and a Youtube video to demonstrate the process.
Make time to be creative.