How to make a pen:

 Finished bullet pens

Posting on behalf of Loyal Blair:


   Follow all safety rules for the use of a lathe.  If you don't know them, learn them now, before using the lathe.

You will need,

• a lathe
• drill bits (size will depend on type of pen you are making)
• a drill press (or chuck for lathe)
• lathe chisel set
• bushings
• mandrel (for lathe)
• assorted sandpaper sheets
• finish for the pen
• pen blank.  Yes, you can make your own pen blank by simply cutting a piece of wood the appropriate size.  

1.  Mark the "center" in the end of your pen blank, by drawing diagonal lines across each corner on the end of your pen blank.  Where the lines cross is the approximate center.  A pen blank is a piece of your favorite wood "about" 3/4 by
3/4 and about 2 inches long.  (Size of pen blank may vary slightly with your kit, as they come in different sizes, different size hole, different size bushings.  Check your kit for drill size and busing size, as well as the pen blank size.

Pen blanks.  These are 2 different
woods glued and clamped together

2.  Using your drill press, drill a hole in the center of your pen blank.  A drill vice is recommended to hold the pen blank while drilling the hole the length of the blank.

3.  Size the pen blank to the exact size or no more than 1/16" longer than the pen barrel tube.

4.  Using Super Glue, glue the pen barrel tube into the pen blank.

5.  Insert the pen blank, with the pen barrel tube into the mandrel, with the bushings on each end.  Tighten the nut on the pen mandrel, rather snug, but don't use pliers to tighten it.

6.  Once the barrel is inserted into the mandrel, insert the mandrel into the lathe.  Select the speed of the lathe, pens are small and can be turned at a faster speed.  I usually use about 2500 RPM but a little slower or faster is OK.

Some pens require 3/8" drill others
its 7mm. The barrel of the pen has to
fit, and is glued in. So, the size is
critical. The whole thing does
not work without the right size.

7.  Set the tool rest close to the pen blank but make sure it wont hit the tool rest by manually turning the lathe to make sure it does not hit anything.

8.  Start with the smaller rounded chisel (also called a "gouge") and, hold the chisel on the tool rest until it just barely touches the spinning pen blank.
9.  Continue turning the pen blank until its within about 1/32 or so as the same size as the bushing.  After the pen blank is rounded off with the gouge, you may use a straight chisel to "straighten" up your pen blank.

10.  When the blank is now round and about 1/32 larger than the bushing, turn off the lathe.

11.  Remove the tool rest, you wont need it for sanding.

12.  Start with the course sandpaper, and work down to a very fine sandpaper.  I usually start with 80 grit, then 110, then 220,
and lastly 600 grit (very fine).  After sanding with 600 grit paper, your pen should be "very smooth".

13.  Remove as much sawdust as possible...you can use a vacuum, an air compressor or even just hold a paper towel on the spinning pen blank to remove as much sawdust as possible.

Roughed in.  Notice the pen mandrel and the bushings.
Assemble yours similar to this on the pen mandrel

14.  Apply the finish.   A few drops of finish on a paper towel or rag, and then spin the pen barrel.
"Burn in" the finish, that is, contact the paper towel with a little bit of finish on it and hold it there until it warms up.  The friction will cause it to warm up.

15.  After the finish is applied, let it dry for a half hour or so.

16.  Assemble the pen as per instruction on the kit.