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PROJECT PEN KITS
Letter Opening Kit
Code: 700297
PREPARING THE BLANKS, HINTS & TIPS
Preparing a wooden or acrylic/polyester
blank for a pen mandrel.
1. Cut a blank to the length of the tube,
minus approximately 4mm.
2. Using the recommended drill bit, drill a
hole lengthwise through the blank.
Note: This kit requires 5mm of the tube
remains exposed at the blade end of the
handle, mark with a pencil.
When inserted into the blank this will
leave approximately 1mm of the blank at
the other end to allow for trimming.
3. Apply epoxy glue, Polyurethane glue or
gap filling cyanoacrylate (super glue) to
the tube.
Insert the tube into the blank with a
twisting motion to spread the glue evenly
inside the hole up to the 5mm mark.
4. Allow the adhesive to cure.
5. When cured, square the top 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.
6. Take the excess material down flush
with the end 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:
951192
Drill Bit Size:
7.5 mm
Minimum Blank Size:
19 mm x 19 mm x 50 mm
Tips/Hints
• 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 blank onto a
pen mandrel according to the diagram.
2. Secure the bushings and blank 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 blank down
to become the Letter Opener Handle
with the profile of your choice.
5. Turn the blank 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 Letter
Opener Handle.
7. Finish the Letter Opener Handle 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
Layout parts according to diagram A.
1. Introduce the End Cap into the top
of the Handle. Using the 12.1mm
Bushing to safeguard the protruding
tube; press the End Cap into the
Handle.
2. Introduce the Handle Ferrule onto the
protruding brass tube, carefully press/
push the Ferrule onto the Tube and up
against the Handle.
DIAGRAM A
3. Introduce the Threaded Insert into the
Brass Tube and press home.
4. Pass the tang of the Blade through
the Blade Ferrule and screw into the
Threaded Insert in the Handle.
5. Ensure the locating ring on the Blade
Ferrule is aligned with the recess in the
Handle Ferrule and tighten firmly.
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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