Changes

Pen blanks typically come in sizes of around 3/4" x 3/4" x 5-6" which is suitable for most small pens. Larger fountain pens may need 1" x 1" blanks. Exotic hardwoods are popular, as are various engineered acrylics with color patterns. These can be acquired from the suppliers, above, as well as many other sources. Several PS:One members use exotic hardwoods in their projects; it may be possible to recycle scrap for pen blanks. And it is possible to laminate woods together to make a multi-layered blank.

Pen blanks typically come in sizes of around 3/4" x 3/4" x 5-6" which is suitable for most small pens. Larger fountain pens may need 1" x 1" blanks. Exotic hardwoods are popular, as are various engineered acrylics with color patterns. These can be acquired from the suppliers, above, as well as many other sources. Several PS:One members use exotic hardwoods in their projects; it may be possible to recycle scrap for pen blanks. And it is possible to laminate woods together to make a multi-layered blank.

== Trimming and Drilling the Blank ==

== Cutting and Drilling the Blank ==

[[File:DrillingPenBlank.jpeg|thumb]]Most pens are made in two pieces, in which case the kit includes two tubes. The pen blank needs to be cut to length in pieces, each slightly larger than the length of the respective tube. Marks should be placed on the blank before cutting so orientation can be established later, which is an important consideration to ensure the grain matches. A mark should also be placed at the center of each pen blank on one of the small ends. The opposite end can then be clamped in a 4-jaw chuck on the lathe. A 1 MT Jacobs chuck can be inserted in the tailstock of the lathe, and one of the following brad point drills, based on the tube diameter as specified in the kit instructions, can be inserted in the Jacob's chuck. The Jacob's chuck is currently hanging on a wall rack next to the Wen lathe. Drills are stored inside the blue "Pen Turning" box. The brad point bits are designed to bore into the wood without wandering and are substantially more expensive than traditional drill bits. '''Please use these drills only for pen turning and make sure they are returned to the blue "Pen Turning" toolbox so that they do not get lost in the woodshop.''' The following drill sizes are available at present:

[[File:DrillingPenBlank.jpeg|thumb]]Most pens are made in two pieces, in which case the kit includes two tubes. The pen blank needs to be cut to length in pieces, each slightly larger than the length of the respective tube. Marks should be placed on the blank before cutting so orientation can be established later, which is an important consideration to ensure the grain matches. A mark should also be placed at the center of each pen blank on one of the small ends. The opposite end can then be clamped in a 4-jaw chuck on the lathe. A 1 MT Jacobs chuck can be inserted in the tailstock of the lathe, and one of the following brad point drills, based on the tube diameter as specified in the kit instructions, can be inserted in the Jacob's chuck. The Jacob's chuck is currently hanging on a wall rack next to the Wen lathe. Drills are stored inside the blue "Pen Turning" box. The brad point bits are designed to bore into the wood without wandering and are substantially more expensive than traditional drill bits. '''Please use these drills only for pen turning and make sure they are returned to the blue "Pen Turning" toolbox so that they do not get lost in the woodshop.''' The following drill sizes are available at present:

With the pen blank inserted in the lathe chuck in approximate position but with the jaws loose, slide the tailstock with the Jacob's chuck and the drill installed, and the tailstock ram fully retracted, to contact the stock. Lock the tailstock. Push the stock onto the brad point of the drill at the marked center point and then tighten the jaws on the other end of the stock. Power on the lathe and crank the tailstock ram to drill into the stock. Once the ram limit is reached, stop the lathe, retract the ram, side the tailstock closer until the drill makes contact with the bottom of the hole, lock the tailstock, and repeat.

With the pen blank inserted in the lathe chuck in approximate position but with the jaws loose, slide the tailstock with the Jacob's chuck and the drill installed, and the tailstock ram fully retracted, to contact the stock. Lock the tailstock. Push the stock onto the brad point of the drill at the marked center point and then tighten the jaws on the other end of the stock. Power on the lathe and crank the tailstock ram to drill into the stock. Once the ram limit is reached, stop the lathe, retract the ram, side the tailstock closer until the drill makes contact with the bottom of the hole, lock the tailstock, and repeat.

Pro Tips: When the drill emerges from the end grain, it can tear out wood. Make sure the blank is long enough so that the pen tube can be inserted in the hole without contacting any part of the hole with tear out. Masking tape placed over the end grain can help reduce tear out. Place tape on the drill bit so one knows how far to drill into the blank.

Pro Tips: When the drill emerges from the end grain, it can tear out wood. Make sure the blank is long enough so that the pen tube can be inserted in the hole without contacting any part of the hole with tear out. Masking tape placed over the end grain can help reduce tear out. Place tape on the drill bit so one knows how far to drill into the blank. Also, keep in mind that this is an inexpensive lathe with poor runout, so some difficulty drilling is expected.

 

 

[[File:PenTubeInsertion.jpeg|thumb]]Once the blank is drilled, the next step is to glue the metal pen tube inside the hole. Make sure the tube fits without too much force, and that it can be positioned so that excess wood extends beyond both metal ends. If tear out has occurred, take care in positioning the tube so that the area of torn out grain does not contact the tube itself, if possible. Either 2-part epoxy or CA glue can be used. Sand the outside of the tube if it is not rough already from the factory. Cover with a thin layer of glue. Use the conical insertion tube (stored in the Pen Tools box) to inert the tube into position inside the blank, and let the tube dry.