After selection, co-ordination with the Pen Kit, and getting the drill bit..bushings and Instructions, it is time to cut the blanks.
Marking the Blank :
First, I take the brass tube and mark on the blank where I want to cut it. And mark it as shown.....
The configuration of the lines on the blank are as follows:
The line down the center tells me how it was cut after it is apart. Using this line, I can make the pen so the pattern of the blank will line up. I also put arrows pointing towards each other to assist with which direction it should go. I pay close attention to that during the turning. In many cases the bushings are different sizes, for instance the nose cone, is a different size than the middle or ends…you need to keep that straight. The markings help with that, as the pen is turned you need to pay attention the that. After the pen is turned, you obviously can not mark it like this, so you should keep the bushings with the pen and measure the pen diameter to them.
The last piece shown with the "X" is throw away....however, I do keep it in the container, just in case I break one of the other blanks. It will not match as well, but better than nothing, it I decide to move forward with the pen after a tragedy.
First mark and cut the first piece, then mark the second, this is taking the width of the blade into account.
Cutting the Blank:
I cut mine on the band saw, I have this jig that I use. It is from Penn State. I also just use a miter gauge sometimes…not rhyme or reason which one.
I also have built this jig for my Table saw.
Either way works fine. I have chosen to use the bandsaw as the blade is just a little thinner.
After the blank is cut, I put them back into the container, and then begin the drilling process, covered in the next blog.
If I had a jig like yours on the BS, I'd have cut it in half after the 3rd use! Good process with the marking, I try to do the same when it matters, but often cut/sand away the marks and have to guess.
