How I turn pens and my setup.

[terrydowning]

In a different thread regarding pens I offered in text how I did barrel trimming.

Rather than highjack that thread I'm posting my setup and operations in this thread.

First I decide on the style of pen and timber to use. Once that is determined, the specific operations are decided on. For this thread I'm using a single barrel pen called a long clicker from Craft Supplies USA. I ordered this kit from Exotic Blanks

So getting started.

My first step is cutting the blank to approximate length and turning it round before drilling.

I do the cutting on my Nobex 110 hand miter box because it's setup, accurate and I can have it cut faster than I can change over to the table saw. I then drill holes in the center of each end to accommodate my live center and drive spur and turn the blank between centers like any other spindle.

Mounted and ready to turn
[ATTACH]19289[/ATTACH]

It's Round
[ATTACH]19290[/ATTACH]

As previously stated I turn my blanks round before drilling. I do this because I drill using the lathe option and use a Collet Chuck to hold the blank. I find this very helpful for long blanks that must be drilled from both sides. This particular blank is 4 5/8 inches long and I need to through drill it so I need to drill from both sides accurately.

Mounted in collet chuck ready to drill side 1
[ATTACH]19291[/ATTACH]

Side 1 drilled
[ATTACH]19292[/ATTACH]

The blank is then removed and flipped in the collet so I can drill side 2
[ATTACH]19293[/ATTACH]

Now that the drilling is done. I can glue in the brass tube. No photos for that. Wipe down the blank with solvent of your choice and glue in to new hole with adhesive of your choice.

Next will be trimming and squaring the tubed blank.

[terrydowning]

For trimming and squaring I use my drill chuck and the sanding disc.
[ATTACH]19294[/ATTACH]

I elevate the tail stock slightly to hit fresh spots on the sand paper. Just using the center will wear the center out quickly. You can see wear marks in the sand paper.
[ATTACH]19295[/ATTACH]

Adjust the quill so it is close to but not touching the blank. To sand the blank move it toward the sanding disc with a slight turning motion.
[ATTACH]19296[/ATTACH]

Loosen the quill, flip the blank and repeat.

The results speak for themselves

Before Not completely square, close and it still needs to be trimmed so the brass meets the timber.
[ATTACH]19297[/ATTACH]

After trimmed, square clean and ready for turning
[ATTACH]19298[/ATTACH]

Next is turning the blank between centers.

[terrydowning]

I have mentioned before that I rarely use bushings and mandrel when making pens anymore. Instead I Turn the blank profile between centers (TBC) and use calipers to measure everything.

For TBC you need a Dead Center to drive the blank, a Live Center to support the blank, a shorter tool rest so you can get close to the blank.
[ATTACH]19299[/ATTACH]

Mounted with tool rest positioned. I can't stress enough the importance of keeping the tool rest close to high speed spindles. The farther your tool rest is the more likely your to experience chatter and catches.
[ATTACH]19300[/ATTACH]

Measure the actual Pen Hardware. Don't trust bushing or spec sheets, they will get you close, but for the best possible fit, measure the hardware. The instruction sheet has the bushing diameter at .444. I have been told that the human finger can detect a difference as low as .001 on mating surfaces.
[ATTACH]19301[/ATTACH]

I turn the ends down first and measure. turn some more and measure, until you are there.
[ATTACH]19302[/ATTACH]

Once the ends are down close to size finish your profile. I do recommend stopping occasionally and sharpening your chisel.

Or this can happen.
[ATTACH]19303[/ATTACH]

Reasons this failure occurred.
Skew not sharp enough!
Insufficient glue bond between the tube and the blank.

I have prepared another blank and hope finish tonight. pics of assembly tomorrow. I use the SS for that too.

[dgale]

Wow - thanks for taking the time to put all this together. Very imformative as I had no idea how folks were making pens. I look forward to seeing the rest of the operation.

[terrydowning]

Just remember, this is one of my ways, I do have others. There are many ways to go about making pens up to and including a sharp knife and a stick or feather.

Ultimately everyone has to come up with their own set of tools and procedures that they fell works best for them.

[dgale]

I take it from the pictures above that the blanks come imbedded in wax?

[terrydowning]

Actually, that particular blank was from a root ball from a rose bush I removed earlier this spring. I cut it up and managed to get 4 blanks out of the root ball.

There were some gaps, so I mixed up some Polyester Resin (PR) tinted blue, placed in a mold and filled the gaps with the PR. I put this under pressure to squeeze the PR into the gaps and let dry. Too bad it failed, it was going to be pretty when finished, the grain is really interesting and the blue filler will stand out nicely. I have 3 other blanks, we'll see what happens with those.

The next one I will try is Afzelia Burl I got in a blanks exchange. Tubes is glued in, I will be trimming and turning tonight. (I Hope)

[dgale]

Actually, that particular blank was from a root ball from a rose bush I removed earlier this spring. I cut it up and managed to get 4 blanks out of the root ball.

There were some gaps, so I mixed up some Polyester Resin (PR) tinted blue, placed in a mold and filled the gaps with the PR. I put this under pressure to squeeze the PR into the gaps and let dry. Too bad it failed, it was going to be pretty when finished, the grain is really interesting and the blue filler will stand out nicely. I have 3 other blanks, we'll see what happens with those.

The next one I will try is Afzelia Burl I got in a blanks exchange. Tubes is glued in, I will be trimming and turning tonight. (I Hope)

Interesting - the small size of the stock required for pens certainly presents a whole new range of potential wood supplies.

[terrydowning]

I don't have scraps anymore.

I have cutoffs and smaller stuff goes into Potential Blank Material bin.

I throw very little away anymore. Example, I just did a project that left me a 1" x 3/4" x 7" cutoff, It will become a pen blank. The cutoffs from that will go back into the "Potential Blank Material bin" for possible future use in segmenting or scalloping material, Possibly a finial or a center band.

Softwood cutoffs from dimensional lumber and such still eventually makes it to the burn box. I'm just not hanging on to 4" 2 x 4 cutoffs very long.

About the only thing that goes to the trash is plywood cutoffs I don't see any future use for either due to size or condition.

[db5]

Or this can happen.
[ATTACH]19303[/ATTACH]

You forgot to mention an important part. What are the magic words you used when this happened to make sure it doesn't happen again?