If the cartridge is too loose, hold it in with strong glue. If it’s too long, hold it in place with tape.
For best results, before you begin cutting, soak the feather in hot water until it bends easily, then harden it again in hot sand. [3] X Research source
See the Things You’ll Need section below for additional tools before you buy. The same source may be able to sell you those tools. This guide will work for any type of pen kit. Rollerball pens are slightly easier to assemble, but twist pen kits are usually the cheapest option. [4] X Research source
Line up the two brass tubes from your pen kit. Cut the blank a bit longer than this length. The other dimensions don’t matter, as long as the blank is significantly larger than the desired pen size. A 5" x ½" x ½" (12. 75 x 1. 25 x 1. 25 cm) blank should fit most pen kits. [5] X Research source
Most pen kits come with two brass tubes, but some use three. These may be different lengths, so use a different tube for each measurement. Draw a pencil line across the blanks so you can easily line up the grain. [6] X Research source
The most common sizes are 7mm (roughly J bit or 9/32") and 8mm (roughly O or 5/16"). [9] X Research source If using imperial drill bits, you may want to test on scrap wood first to find the best fit. A slightly loose fit should turn out fine if you use extra glue. [10] X Research source
Cyanoacrylate (CA) glue and 5-minute epoxy are popular choices. [13] X Research source If you use polyurethane glue, wait until the final stage, when you’re ready to assemble. This glue foams up as it cures, which can ruin the fit. (This is a possibility with all glues, but most pen makers prefer the convenience of gluing at this stage instead of leaving the tubes loose. )[14] X Research source
Now’s a good time to check the inside of the tubes for glue. Scrape it out using any tool. You can use a sanding jig instead, but it may take quite a bit of setup. [15] X Research source
Check the kit instructions for recommended bushing size. If you really don’t want to buy the pen mandrel you can mount each blank separately on a 60º live center instead. [16] X Research source Shaping each piece separately will be much harder for a beginner, however.
If you don’t have a lathe, mount a sanding drum onto your drill press and hold the blank against it. [18] X Research source You’ll have much less control, but no one wants to buy a $300 lathe for a $2 pen.
There are plenty of variations on this exact sanding process, so don’t feel that you have to use these exact grits. High-quality pens may be sanded up to 1200 grit at this stage, using mesh abrasive cloths. [19] X Research source
Rub on paste wax for a shinier pen. [23] X Research source
Press the pen cap into the upper brass tube. Press the twisting mechanism into the lower tube. Before you press, lay the mechanism next to the blank, and twist to extend the tip. Note how far you’ll have to press it in order for the tip to just barely protrude. Press the pen clip and cap onto the upper blank.
