This is a ‘Raw’ pen. The acrylic blank, brass tubes that line it, the tip, center ring, clip, insert and the transmission (extends and retracts the insert when the top part of the barrel is rotated)

After deciding what material to use with a specific combination of hardware, the next step is to cut the blanks to the appropriate length.

Pictured here are one slimline (both top and bottom are the same length) and four ‘Designer’ blanks which have a longer lower section.

After being cut to length they are drilled to accept the brass tubes which is then glued in place.

I try to do this process in small batches – I will select the materials for 5 or 6 pens and prep all the blanks at once.

24 hours for the glue to dry and we’ll move on to the next step in the process….

….which is to mount the blanks on the lathe so they can be shaped. These are 3/4″ square pieces of Bethlehem Olive Wood – 3/4″ square is the most common ‘cut size’ for blanks because they can be used for any style pen. If I am cutting my own blanks I will reduce the size to 5/8″ because I seldom do oversize pens.

Ready to get started with the turning

Once the blanks are mounted they can be roughed out….

Turning the blanks from square to round

The bushings at each end of the blank sections provide guidance on the finished size required so that the transitions from wood to hardware are clean. The blanks will be turned with a skew chisel until they are very close and then the final dimension will be achieved in the sanding process..

Shaped, sanded and ready for finishing

Now the blanks are pen shaped and ready to be polished and assembled. Note the tenon cut on the right hand end of the left hand blank – this is where the center band is seated when the pen is assembled…..

The finished pen