1. All elements of this presentation are Fair Use and meet copyright laws for educational purposes. This presentation may not be copied, sold, or used for commercial purposes of any kind. April 2009

2. Pen Turning Rick Long & Steve Scherer Henrico County Public Schools

3. Decide on your material and design.

4. The finished pen should have a pleasing oval or a cylinder shape.

5. Get checked-out on the tools you need to use. Band Saw

6. Get checked-out on the tools you need to use. Drill Press & Clamp

7. Get checked-out on the tools you need to use. Super Glue

8. Get checked-out on the tools you need to use. Hand Drill and Reamer

9. Get checked-out on the tools you need to use. Lathe and Lathe Tools

10. Get checked-out on the tools you need to use. Sandpaper & Finish Polish 120, 180, 320, 400, 600 grits

11. Get checked-out on the tools you need to use. Pen Press Note: a good wood-faced bench vise will also work if you are very careful.

12. Review the Lathe Safety Quiz with your teacher. Also, don’t forget to wear these

13. If working with wood, mark it to align the grain.

14. Cut your material just slightly longer than the pen barrel.

15. For typical “slimline” pens use the 7mm drill bit and vise on the drill press to bore out your material.

16. Top view of wood in vise Wrong Right

17. Use sand paper to lightly sand the outside of the brass pen barrels. Unsanded Sanded This will help the glue to secure the pen barrel inside your wood.

18. If working with super glue, apply it to inside of your material. Warning: Do not glue your fingers together!!!

19. Gently blow out excess glue. Warning: Do not breathe super glue fumes OR GLUE YOUR LIPS TO THE PEN!!!

20. Roll the sanded barrel in the excess glue. Roll it again as you insert it into your material to make sure it is well glued. Warning: Do not glue your fingers to the wood!!!

21. Let the super glue dry thoroughly BEFORE moving on to the next step. Absolute minimum of 30 minutes!

22. Cut off any excess material beyond the end of the glued barrel. Cut Here Warning: Do not cut the brass barrel or your pen will be too short! End View Side View Cutaway

23. Use the 7mm reamer vise to clean out the dry glue and square the end of your material. Recommendations: 1.Make sure reamer is not bent and is tightly aligned in drill chuck. 2.Wipe down reamer between uses. 3.A small drop of 3-in-1 oil on reamer will help smooth reaming process.

24. Align your material if using wood. Remember the marks you made?

25. Mount your material on the lathe spindle. Warning: Don’t use worn-out spacers. This will cause the ends of your pen to be too narrow. Be sure to use the 7mm spacers.

26. Be sure to tighten the lock nut.

27. Adjust and tighten the tool rest. Just below the centerline. About ¼” from material.

28. The tool should cut at about the centerline of the stock.

29. Adjust & tighten the tail stock. It holds the spindle securely.

30. Make sure the material does not hit tool rest. Rotate the spindle by hand.

31. Have your teacher review your set-up before turning the lathe on.

32. You will use two cutting tools. Gouge: For Rough Cutting Skew: For Fine/Finish Cutting End View

33. Check lathe is set on low-to- medium speed (400 rpm). This should already be preset by your teacher.

34. Power up the lathe on low-to- medium speed (400 rpm).

35. Use the gouge tool for the rough cutting.

36. Hold the gouge cutting tool level and firmly with both hands. Let the tool do the work!

37. Use the skew tool for the finish cutting. Readjust the tool rest as your work becomes smaller in diameter.

38. Work your way up from 120 grit up to 400 grit for wood. Up to 600 grit for composites. Remove the tool rest to finish sand with medium-to-fine sandpaper.

39. Our wood polish is heat activated. It only takes a drop or two on a paper towel to do the job.

40. Our wood polish is heat activated. Finished wood should feel warm and dry, NOT “sticky”.

41. Finished barrels ready for assembly.

42. Lay out the pen pieces. Line up the wood grain if working with wood.

43. Upper Barrel: Tap on the cap and clasp Note: A good wood-faced bench vise will also work if you are very careful.

44. Do this BEFORE pressing refill holder into pen! Lower Barrel: Press Pen Tip into place.

45. Press until brass just disappears to ring indentation. STEP 1 STEP 2 Lower Barrel: Press Refill Holder into place.

46. Finished Assembly

47. Other Possibilities

48. 1.Keep all of your pen pieces in the bag provided. 2. Wrap drying pieces individually with wax paper. 3.Place a piece of masking tape with your last name & Per. # on it on your bag. 4. Your teacher will collect these at the end of each period for safe keeping.

49. Additional pen kits cost a minimum of $6. Warning: If you lose any pen kit pieces you may need to buy a second kit to complete your project.

50. Turn in your completed pen to your teacher for grading.

51. Pen Materials Resources & Supplies (on your own) Penn State Industries http://www.pennstateind.com/store/pen- kits.html Packard Wood http://www.packardwoodworks.com/

52. Any Questions?