Step 5: Every Pencil Needs a Ferrule

The metal ring which attaches the eraser to a pencil is called a ferrule. The biggest problem I had making my pencil ferrule was one of proportion. If the thickness of the ferrule were made to the same scale as the rest of this pencil it would be about 1/4" thick. I chose to compromise on the size of my ferrule. It stands out a bit further from the flat sides of the pencil than it should but it also sets into the corners a bit further than it should. If it were as thick as its scale calls for, it would be really hard to work and very heavy to move. Instead, I chose to use 24 gauge galvanized metal. I purchased three strips, each 72" long. Two of the pieces were 11" wide and the third was 13".

First, I rolled each piece until it made a 23" diameter circle. To add some dimension to the pieces, I rolled the 11" pieces through a double roller, putting the rolls about 1 1/2" from the edges. For the 13" section, I used a metal brake to make a series of bends, each 2" apart. The bends were made at 15-20 degrees which required that I bend one, pull the metal out and turn it over, put it back in and bend the next one then remove the metal...and so on.

Initially, I tried using a spot-welder to join the three pieces but galvanized metal does not weld well. I ended up using pop-rivets on much of it. The bead I rolled in and the way the sections joined gave it quite a bit of strength. More on that in a moment...

In order to mount the ferrule to the pencil, I had to round the corners of the pencil. This gave some good, strong mounting points. I built a frame of 2" x 2"s and plywood. I screwed and glued four pieces of plywood to two 10" lengths of 2" x 2" in such a way that two of the 2" x 2"s were on each end of the plywood and the plywood formed a box between the two pairs of 2" x 2"s. I repeated this three times to build structure between each section of the ferrule.

I cut three disks of plywood to fit inside the ferrule. One is positioned at each end of the center section. In the last photo you can see the lip formed where the sections meet on the inside. The third one was fastened at the edge of the bead near the top in the photo. If the ferrule were transparent, you could see one plywood box fastened to the end of the pencil with a plywood disk on top, followed by a taller plywood box in the center section with another plywood disk and then one more plywood box and a final disk. Building it in this manner allowed me to fasten the first plywood box and disk to the end of the pencil before I slid the ferrule in place. Then I built the next box and screwed it in place so that the 2" x 2"s of it lined up with the ones in the first box for added strength. All joints were glued and screwed. Then I was able to reach down inside the ferrule to screw the center box into place then screwed the next disk in place. Next was the last box followed by the last disk. 

At this point. my project looks like a pencil but is lacking an eraser. There is a plate of plywood about 2" below the rim of the ferrule which will allow an eraser to be mounted.
<p>many years back as a young man learned a technique to remember things ( any thing) which are in sequence. I could remember and recall those more than hundred item names without missing the sequence. The trick was to link one after one by building up a story. While making up the mental picture, the rule was not to visualize it as normal size shape or as single number. Say if the first object was a screw driver, visualize that as big as a sky scraper, next object say was a book, get a mental picture as hundred of flying books are coming and landing on top roof of the screw driver. Go on adding other items sequentially , making sure mental image is as outrageous possible. This process make neurons activity in our brain more profound, usually these don't erases easily, and we can recall the sequence easily. This huge pencil image and the its making has fired so many neurons, I wander , how long this will remain in my memory hard disc !</p>
I think you would get pulled over by the cops for that.
Nonononononononoonononono NO...Weapon of Math Disruption
lol. couldnt help it
Ok i gotta admit it, your comment is pretty cool :)
Could be!
I just saw that you won! I'm so very excited for you as this is one of the best instructables and out of the box thinking I've ever seen! I can't wait to see what you come up with next!
Thank you poofrabbit. I appreciate your kind comments.<br><br>I checked out some of your instructables. You are quite artistic.<br><br>I am working on my second instructable and hope to be ready to post it in a day or two.<br><br>Keep up the good work.
A giant &quot;Thank you&quot; to everyone who has taken the time and effort to view my first Instructable. I greatly appreciate having been selected as a winner in the &quot;EXTREME! Challenge&quot;. I am considering mounting the GoPro camera on the tip of the pencil. That way, I can show the world from &quot;The Pencil Point&quot; of view!
5 star's and a vote. This is a project that I normally wouldn't have looked at, but after reading the first two paragraphs you got me really curious. Well written and well thought out project. Really took me on your journey to build this. Will follow and hope for future projects from you sir! <br>
Thanks a lot FreeStrange. I hope to add more Instructables. Odd things come out of my shop at times...like the Model A Ford pictured as my icon here.<br>
A first I thought it was just a model with a regular pencit, but wow! I am impressed!<br>
You found me out! It really is a regular pencil. The bigger secret is that I figured out a way to shrink my wife's truck. Now if I can only figure out how to get to back to full size and save my marriage!<br><br>Just kidding. thanks for your kind remark.
Incredible work.<br><br>I have really wanted to imitate.<br><br>It looks like a pencil Land of the Giants!
I like that DrakerDG!
showed this project to a couple of friends, they laughed...tis an interesting project, what brought it back into your mind after all those years?
I'm glad your friends liked it. <br><br>I have many things that play with proportion around my place, like a 24&quot; tall, soft-serve ice-cream cone and another pencil that is 4' long. I have some over-sized coins, some extremely undersized coins and other &quot;odd&quot; stuff.<br><br>Seeking a project which I could tie into my business, that old pencil came to mind. <br><br>Thanks rymndgeekyguy!
most interesting, I certainly hope you give more instructables in the future, live long and post awesome!
Neat instructable, and great pics! <br><br>I originally clicked on it because it shares the title of an interesting book by John Taylor Gatto, also formerly a public schoolteacher for at least 30 years, who has a lot of intriguing points about education.<br><br>Are you going to try to make one that writes now? :)
I was thinking it wouldn't be too hard to mount a briquette into the tip, sharpen it up and scribble away...
Mounting the briquette would be pretty easy but grasping a 20' pencil that weighs 240 pounds might be a bit tough.
Move the paper, not the pencil ;)
&gt;&gt;---&gt;sfreeman1 - <br>Looked up something for you. Not sure it will fit the bill but all you do is Google Graphite Rods<br>http://www.naccarbon.com/<br>or http://www.graphitestore.com/<br><br>Slap one of those into a wood tube cut from a pole and Voila!<br>It would be a giant pencil you can actually write with.
It would be pretty easy for me to add graphite to this pencil but there is still the problem of writing with a 20' pencil that weighs 240 lbs.<br><br>Thanks for your efforts.
hehe...yes...also I tried to google for a super giant eraser and found none that would fit a pencil that huge...alas you'll have to make sure you don't make any mistakes ;)
Well, Mienja, that's easy. I nevr mack miscakes!
5 stars and +1 vote<br><br>It's sad people think they can win by just adding one word to the title.....At least try to be awesome and put as much in as this project took.
Thank you very much for the 5 stars and the vote (in the contest) and the vote of confidence.
you should use this as a sign for your tutoring business. that way the kids would see it every time they came to be tutored.
One of my students suggested today that I should install it in the yard and put benches alongside of it so kids could sit on the benches and use the pencil for a table to do their work with me. I love it when my kids start thinking &quot;outside the (pencil) box&quot;.
Wonderful. I woudl have made it a red editor's pencil - but that says something about my character. Thinking I should make a red editor and a blue proofer pencil in honor of my Father. Thank you so much for posting this.
I'm glad you've gotten some inspiration from this pencil. I'd love to see your red and blue ones when you finish them. Good luck.
That is very cool, well done.<br>
Insanely great.
That's an awesomely oversize pencil!
Thanks depotdevoid!
You can tell it is a brand new pencil; no one has chewed on it yet!
Great work. I love it.<br>Thanks for sharing.
Thanks cammers. I appreciate each of the kind comments the project has received. I'm hoping they are translating into votes for the contest so my students can gain some new tools for our classes.
Excellent project and a very nice wife to let you use her truck.
Thanks dorybob. It was nice of my wife to let me use her truck but she wants it off of there. I took it to &quot;the dump&quot; the other day and it worked just fine with the pencil on the back. I don't understand why she thinks people will be watching her more closely than the usually do when she drives her truck through town.
Although I would never make this pencil project, I love it! And, I love the fact that it resulted from a childhood memory and teaching lesson to a student.
Thank you bstorer. You might enjoy my website. You will get the idea that I don't teach in the traditional way all the time. www.TheFreemanCenter.com.
Astonishingly great.<br>As a writer, I love the pencil.<br>As an admirer of old pickups, I adore your wife.<br>Fabulous project. <br>Brillinant execution.
Thanks Ricardo. I adore my wife too. Even though she told me this morning that she wants the pencil off her truck pretty soon.
This is wonderful. Thank you for sharing this. I have tutored students and this would be a great conversation piece. I have taught woodworking to some high school students who loved that I would take the time and share my knowledge with them. I like that you a good showing each section and explaining your thought processes to the reader. I have shown this to some co workers who loved it also. Have a great day!
Thanks ironman0104. Once a teacher always a teacher. It seems I analyze much of what I do by &quot;how could I teach this to someone?&quot;. Did you give it a vote in the contest? Thanks!
I love it, and the name is a great play on words.
Thanks guido666. I can't take credit for the title though. One of my employees came up with that as soon as he saw it.

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Bio: Same town for 42 years. Same wife for 38 years. Same old truck for 41 years. Some would say that with all that is the ... More »
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