Thread: level ends

Would you be sanding the ends with the blank sitting on the table of the sander or do you have a jig that holds the blank on a rod through the brass tube? If the former the hole you drilled is probable not perfectly parallel to the sides of the blank which would make the end out of square. You can never get consistent square ends this way. If the latter the table and/or jig might not be square to the sanding disc and that's where the error comes in. Once set up correctly you should get square ends.

I made a very simple jig for the mitre gauge that came with my disc sander that used the transfer punches/pen disassembly tools. There are similar jigs that you can buy but if you have a table saw it is very simple to make. To use you place the closest punch that fits the inside of the tube into the V groove and clamp it down. slide the blank over the punch and sand it. When you get very close to the brass twirl it a little until the brass is just shining all around. Twirling evens up any tiny discrepancies of the jig. The picture is one I have posted before.

Pete

+1 for QCInspectors jig. Works a wonder.

I also use a Jet belt sander, set vertically. Same thing - just a slightly different jig.

Tip on the "see shiny brass" is absolutely correct. A light tough!

these jigs in the right hands work a treat if you still experience issues on trimming the blanks purchase an end trimmer I don't think they are that expensive and you will avoid stuffing up blanks. enjoy being hooked on making pens.

Originally Posted by mature one

these jigs in the right hands work a treat if you still experience issues on trimming the blanks purchase an end trimmer I don't think they are that expensive and you will avoid stuffing up blanks. enjoy being hooked on making pens.

I tried the disc sander but, without a jig I had too many stuffups. So I now use the barrel trimmer in the drill press, but with three strict rules: (1) The shank of the trimmer must be a very good fit . (2) The trimmer cutters must be sharp! (3) Very light touch and stop as soon as the brass end starts to shine.

I am certainly no expert on making pens, having only started around Christmas time on my cheapo Chinese 12 inch lathe. BUT after trying a few things, the pen mill is the best to use. I have it pretty much connected to my old electric variable speed drill all the time. The battery charger drill just isnt powerfull enough, or maybe the battery has had it. I just clamp the blank into my old triton super jaws and hit it with the pen mill until the brass is shiny. I did buy the upgrade pen mill recently from TimberBits but havent tried it yet. I think it has more teeth that the standard one.
Paul

Pete it just sunk in what I'm doing wrong. I rarely have the hole drilled dead straight so of course if I just even up each end by hand there will most likely all sorts of unevenness

What are the jigs called if I want to buy one? I'm sure I could make something but its something I might add to an order down the track!

I looked at timber bits and gary Pye but couldn't find them so maybe the venders in Oz don't sell them. Here is one from the US as an example of a store bought one. Pen Blank Squaring Jig / Sanding Jig – Turners Warehouse This is another type but more futzing to make and expensive. Barrel Trimming Sleeve Set & Squaring Jig Combination: Arizona Silhouette

I have seen where someone took a V-block used in metal machining to do as I did since they had it. A block of wood and any kind of clamp (a hanger bolt and bar of wood for example) to hold the punch is a lot cheaper than the above. If you don't have a table saw to make one perhaps one of the members living near you could cut it for you.

Pete

Pete

I hear of so many pen makers blaming the pen barrel trimmers for a poor finish or "blowing out blanks" whilst trimming. If you choose to use the pen barrel trimmers keep in mind that they use a "cutting edge" that needs to be maintained. A touch up with a diamond plate every now and then is quite simple to do and keeps them in prime condition.

I no longer use a barrel trimmer and have never used a sanding disk with or without jigs. I have Vermec's brilliant ER-25 & ER-32 Collet Chucks, so all my drilling and trimming is performed using them to hold a blank that has previously been "rounded between centres."

I'm thinking if I get squared off pieces of wood, drill straight holes in the ends and glue in different size transfer punches into each one it would be pretty simple right? It means the punches can't be used for anything else and I will have 4 of 5 separate little units but that sounds ok to me

That would work if you are able to drill them perfectly. You can't do it for the blanks so are you sure you would be successful with jigs?
If anything drill out a block and turn it between centres to make a perfectly round cylinder.
I still think sawing or routing a groove is easier.
You can put the punch in a drill chuck in the tailstock and stick sandpaper to a piece of melamine or MDF on a faceplate. Downside is the little piece of sandpaper wears quickly.

Pete

I have a drill press so if the wood is squared away I can drill straight. I'll give it a go

I've ended up putting the punch in a drill chuck!!! At least its easier to see! Got some ready to turn so I'll see how they go