Step 7: Final Turning - Top Barrel

Now the the pen has been rounded a bit you can start on finishing the barrels up. I start with the top one. To achieve the smooth finish on the acrylic necessary for a scratch-free finish, you will need to know how to bevel a skew chisel to make fine sheering cuts. The video I made shows the proper method for making these cuts. Hold the tool so it has a substantial amount of support. Then touch the bevel to the work-piece and lean it into the material and begin shearing off fine shavings. A tennon is also cut (to accept the center-ring) using a parting tool and the sizing ring (the largest of the bushings). When the sizing ring fits over the tennon snugly that means the center-ring will fit well too. The rest of the Barrel is shaved down until it's just about flush with the sizing ring. Remember not to make this too close of a fit since sanding needs to be done.
before putting glue on the tubing take a slice of potato at put in tube ends or wax works to it keeps glue from getting in
I always love seeing how things like this are made, great!
Glad you like it.
I've made 100's of these pens. People love to get them as gifts. A tip for your marking and cutting... Before you cut your blank draw an elongated triangle on one of the sides. When you chuck it up you just line up the split triangle drawing. This ensures your top and bottom are correct as well as keeping the pattern in the material lined up and not having one end flipped around.
Thanks for your tip. Usually the end cut with the band-saw will be a little more rough then the factory cut edge, so it's easy to understand which end is which. If the blank has enough figure to it (usually it does) it helps me to line the grain (or figure, if acrylic) up for continuous flow through-out the barrels. However, I have to re-align the figure once the barrels come off the mandrel and I'm assembling the pen. Also, for the Round-Top European, a tennon is turned in for the top barrel's center-ring and you usually can't notice that time has been taken to align the figure.

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Bio: I love wood working, metal working, science and technology. The areas of woodworking I'm most interested in are turning, furniture making and other small ... More »
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