Carved Pen With No Lathe

WHAT!!! ANOTHER PEN!!

This is not just any pen, it is MY pen, and few out there have one like it. For Christmas, I made a bunch and gave them out as gifts, but I wanted one for myself and thought it would be a good time to experiment with a bit of carving in the shaft. So this is kind of an experiment for me.

Tools needed

#4 Hand plane setup for smoothing: http://amzn.to/2hc6LQZ

Combination Square: http://amzn.to/2klehHq

Brace: http://amzn.to/2hPEs9Y

Drill Bit Set: http://amzn.to/2hZVT5T

File set: http://amzn.to/2l0czdB

Digital Calipers: http://amzn.to/2l03DVt

Supplies Needed

Pen Kit: http://amzn.to/2kOBqoD

Pen Blank: http://amzn.to/2jZDR3O

Shellac: http://amzn.to/2kl4rFC

Super Glue: http://amzn.to/2kw9gh4

Drill out Blank

First, use the calipers to measure the brass tube in your pen kit and find a drill bit with that exact size. Mine was 13/32." Next, drill out your blank as straight as possible from end to end. The brass tube should be a tight fit in the hole. Some people like to roughen up the tube before inserting it and adding a bit of super glue to make sure it does not move.

Shape the Blank

I love a hexagon on the pen shank as it feels fantastic in the fingers. To mark it out, I find a bolt that fits nicely in the tube, then use the head to mark out the shape of the bolt head on both ends. Next, I can clamp it into the vise and plane down each face one by one down to the line. With a sharp #4 this takes no time at all. Lastly, I will round over the ends until they match up with the head of the pen.

Carve the Shank

I wanted a simple spiral wrapping up the shank so I used a combination square to draw 45-degree lines that wrapped up the shank. Then, with a fine file, I follow those lines to carve in a bit with the file.

FINISH IT!!

I like to keep the corners sharp so I use a file to do a final smoothing on the faces. To apply the shellac, I put it on a bolt in the vise so it can spin. I apply 2lb cut shellac in 6 thin coats. I sand between coats 2, and 3, then between 5, and 6 with 400 grit sand paper. Lastly, I use the bench vise to press the parts together. And there you have it, a personally carved pen.