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Pen Making Supplies Whistle & Key Chain Kit Instructions Pen Making Supplies
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KIT FEATURES
  • Heavy 24kt Plating
  • Simplified construction through the use of a single brass tube.
 REQUIRED ACCESSORIES
  • 1/2" or larger square stock blanks
  • 7mm HSS drill bit #PK-1173
  • 7mm barrel trimmer. (optional)
  • Epoxy or gap-filling SG-THICK super glue.
Preparing the Blank
  • Cut wood blanks from 1/2" or larger square stock - cut to length of the tube plus 1/8". Grain should run lengthwise.
  • Bore a centered hole lengthwise through the blank. Drill carefully since excessive pressure may cause the drill bit to wander and /or split the blank. Slow the feed rate and back the bit out repeatedly for chip removal. For bes results - use a 7mm HSS drill bit.
  • Glue the tubes - Apply epoxy or a gap filling CA to the tube and insert into the blank with a twisting motion. This will spread the glue evenly. Center the tube within the blank and allow to dry.
  • Square the ends of the blanks with a disc sander or other sanding device. Square the ends 90 degrees to the length of the brass tubes as needed. A 7mm barrel trimmer will also do an excellent job to square the ends by hand.
Turning the Blank
  • Install the blank on a turning mandrel with the appropriate bushing on each side. Tighten the nut snugly and bring the tailstock center firmly against the end of the mandrel. Turn or file the diameter down to any shape that your creativity dictates. For best results, turn the ends of the tubes down to be the same as the diameter of the bushings

Sanding the Blank

  • As with any sanding, progress through a range of grits. The type of wood used and the quality of the beginning surface will dictate your selection:
    • 80-100 grits if rough surface or additional shaping is needed (overly thick)
    • 120-150 grit if fairly smooth and straight.
    • 220-240 for final finish with most domestic woods
    • 320-400 especially on dense or oily exotic woods.
    Fine steel wool is helpful as it doesn't tend to scratch. Sand with the blank spinning. For initial shaping, stick a piece of sandpaper on a board 1-1/4" wide to remove any hills or valleys. Final sanding with the grain (lathe off). To obtain a flush fit with the pen hardware, sand to the exact diameter of the bushings (21/64"). A little heavier look is possible by leaving more material.

Finish & Touch-up

  • Try a finish of your choice but be careful if brushing on a poly, etc. as you can stick the tube, bushings and mandrel together. The following friction polish works well on most woods:
    • 1/3 wood alcohol (methanol)
    • 1/3 white or clear shellac
    • 1/3 boiled linseed oil
    Mix equal parts of the three ingredients in a bottle and shake before using. Apply with a rag to the spinning tube. Keep the rag in contact with the wood to build up heat, thus sealing the finish. Apply two coats.

Assembly

Note: Use a clamp or vise with wood jaws to press parts together, squeeze slowly. Front and rear tubes are identical; they may be made in advance and then mixed and matched.

  • Align key chain parts according to the diagram above.
  • Press tip into the end of one tube and cap into the other.
  • Thread the key ring through the hole in the cap.

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On PenMakingSupplies.com you will find a complete line of Pen making kits, supplies and turning tools for the serious pencrafter. If there's something you can't find just send us an email and we'll be glad to point you in the right direction. Don't forget to stop by our wood working craft site WoodWorkingCrafts.com.

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