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PROJECT PEN KITS
Empress Crystal RollerBall Pen Kit
Code: 951810
PREPARING THE BLANKS, HINTS & TIPS
Preparing a wooden or acrylic/polyester
blank for a pen mandrel.
1. Cut a blank to the length of each tube
plus approximately 2.5mm to allow for
trimming and squaring off the ends.
2. Mark the centre on the end of the blank.
3. Using the recommended drill bit, drill a
hole lengthwise through the blank.
4. Apply epoxy glue, Polyurethane glue or
gap filling cyanoacrylate (super glue) to
the tubes.
5. Insert the tube into the blank with a
twisting motion to spread the glue
evenly inside the hole.
6. Centre the tube lengthwise inside the
blank.
7. Allow the adhesive to cure.
8. When cured, square the ends of the
blank. Using a barrel trimmer with a
guide matching the inner diameter
of the tube or a universal pen blank
squaring jig with a disc sander.
9. Take the excess material down flush
with the ends of the brass tube. (do
not trim beyond the length of the tube
since this may interfere with operation
of the mechanism and assembly).
For more info and
videos scan here
WHAT’S REQUIRED
Bushing Set:
951820
Drill Bit Size:
8.7 mm (11/32”)and 14.7 mm (37/64”)
Minimum Blank Size:
19 mm x 19 mm x 125 mm
Tips/Hints
• If using a wooden blank, draw a short
pencil line lengthwise across the centre
of the blank. This will help maintain
grain alignment when mounting the
blanks onto a mandrel.
• Excessive pressure may cause the drill
bit to wander and/or split the blank.
Slow the feed rate and back the drill bit
out repeatedly for chip removal.
• Roughen the brass tube slightly with
abrasive for better adhesion.
• Certain acrylic blanks are more
transparent than others, especially
lighter colors or blanks with light
colored swirls. To avoid the risk of the
brass tube showing through the pen
blank, paint the tubes white or black
before gluing them in.
• The barrel trimmer guide also cleans
any adhesive that may have gotten
inside of the tube.
TURNING THE BLANK, HINTS & TIPS
1. Mount the bushings and blanks onto a
pen mandrel according to the diagram
(If using a wooden blank, check the
grain alignment).
2. Secure the bushings and blanks onto
the mandrel.
3. Slide the tailstock with a live centre into
place against the mandrel and lock in
position. This is for support; only slight
pressure is required.
4. Using sharp tools, turn the blanks down
to become the Pen Barrel and the Cap
with the profile of your choice.
5. Turn the blanks very slightly oversize,
then sand and polish the ends down to
the same diameter as the bushings.
6. Using successively finer abrasives
gradually sand and polish the Pen
Barrel and Cap.
7. Finish the Pen Barrel and Cap with your
preferred choice of polish.
Tips/Hints
• Don’t be afraid to sharpen frequently
especially when turning acrylics.
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ASSEMBLY, HINTS & TIPS
1. Layout parts according to diagram A,
ensuring the turned Barrels are the
same orientation as when mounted
on the mandrel.
Hint: When removing the blanks from
the mandrel, mark the inside of each
tube where they join to maintain grain
alignment, if using a wooden blank,
during assembly.
2. Press the Cap/Clip Assembly into the
top of the Short Pen Barrel.
3. Press the Centre Band Coupler into
the bottom of the Short Pen Barrel
4. Press the End Cap into the top of the
Long Pen Barrel.
DIAGRAM A
5. Slide the Trim Ring (note the
orientation) over the unthreaded
end of the Nib Coupler
6. Press the Nib Coupler/Trim Ring
assembly into the bottom of the
Long Pen Barrel.
7. Insert the Spring into the Long Pen
Barrel.
8. Insert the Refill into the Long Pen
Barrel.
9. Screw the Rollerball Nib onto the
Nib Coupler to complete the pen.
Tips/Hints
• Use a woodworking vice, one handed bar
clamp, arbor press or a dedicated pen
press.
• Press parts together slowly and steadily
• When pressing the parts together,
CHECK the parts are correctly aligned
with each other and straight. If the part
is crooked or misaligned, it will result in a
poor fit.
Visit the Knowledge blog ‘How To Make A Pen’ for hints, tips and videos
knowledge.axminstertools.com/pen-turning
VIEW OUR FULL RANGE OF
PEN CASES AND DISPLAY BOXES ONLINE
Axminster Tools, Axminster, Devon, EX13 5PH
AXMINSTERTOOLS.COM
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