Make a Refillable Bullet Pen

This pen makes a great unique gift. It’s made by using two 30-06 rifle shell casings to replace the body of a click pen. It’s a fun project, which will take you about an hour to complete. What you won’t see here or in the video is how many shell casings and hours it took to figure out the process to get this pen exactly right. So if you try your hand at this don’t be discouraged if it takes a couple tries.

 

Step 1: Drill out the primer side

What you’re trying to do here is replace the body of a regular click pen with a couple shell casings. Keep mind I figured out this process by trial and error. If you do the steps out of order you may ruin the shells and have to start over.

You’ll have to drill out the primer ends of both shell casings. I used a mini metal lathe with an 11/32 drill bit chucked into the tail quill. You could use a regular drill but the tricky part is finding a way to hold the shell without distorting it. Once you have both shells drilled out, you’ll have to expand the necks. Before can do this you need some measurements.

Comments

[shadow wave rider]

can you make one of these pens with a .22 calibre bullet shell?

[Mrballeng]

The diameter of a 22 shell is too small for the pen parts. You could make a stick pen though.

[snoopindaweb]

Ya..!

[Schmidty16]

hi

[Hoopajoo]

You, sir, are the reason I invested in a HF 7X10 metal lathe! I LOVE this idea (I've always collected pens) and have made a few for myself (I can't seem to keep one when co-workers keep asking for one or 'accidentally' pilfering them). This pen had a very nice weight and feel to it. Definitely a great ice breaker and conversation starter!
I looked for awhile and think I found the donor pen you used. Was it the Papermate Ink Joy?

Thank you for sharing this and for reigniting the desire to pursue a hobby in metal machining.

[Mrballeng]

Great! Looking forward to see what you come up with. You've got the right pen.

[black hole]

This is a REAL ballistic pen. = ) Great job!

[black hole]

PS: You've got my vote.

[Mrballeng]

Thanks! Fingers crossed.

[bond815]

Great project, thanks for sharing your technique. I can't wait to try it.
I have a few questions...

I don't have a doming block. Is there any reason why filing a taper on the end of the casing wouldn't work?

Did you consider using an actual bullet for the tip?

Do you find the brass keeps its sheen over time?

[Mrballeng]

You can file a taper and that should work fine. You could also use a spoon to roll the edge over by tapping it like a hammer. Over time the pen will oxidize like brass does but it's eaisily cleaned right up.

[andrew.spencer.2]

Extremely well planned, executed, and documented, you do fine work sir! You make me want to move 'lathe' up a couple of priorities on my workshop shopping list

[mikeasaurus]

I love this! I had to do a double-take when I first saw it.

(Also, the shopping list is hilarious)

[Mrballeng]

Glad you like it. Took a long time to figure out.

[ilpug]

Awesome job!

[monsterlego]

That is very cool!