Introduction: Stainless Steel Stylus
A great ergonomic stylus mod, that's easy to make!
Step 1: Use a Refillable Sharpie Marker
Unscrew and remove the marker from the stainless steel housing.
Step 2: Cut Off the Ends
Cut off the back end of the plastic marker case using a fine tooth saw or small hacksaw. Remove the inside of the marker by pushing the tip of the marker back into the plastic housing. For this, I used various tools, including a blunt pencil to get it started, then a small nail, then a pair of pliers to grab and pull out the larger felt end from the back side. Once the inky part has been removed, cut off the first section of the front of the plastic housing.
Step 3: Drill Out the Tip
Using a firm grip, or a small vise, grab a hold of the plastic housing and drill open the tip of the marker - the front inside of the maker is tapered, and the plastic is pretty thick here, so you can drill into it without disrupting the integrity of the housing. This will allow the tip of your stylus to fit inside and poke out the front of the marker. I used a 3/16" drill bit for the Samsung S pen, but you may want to start smaller and gradually work your way up in size, depending on the exact dimensions of your pen.
Step 4: Test the Fit
After drilling the opening of the marker, I would push the S pen through the back and out towards the front. If the pen didn't come out of the front enough, I would take it back out and drill some more. If you don't want to go up in drill size, you can angle your drill and rotate it as you are drilling to "chew up" a bit of the plastic on the sides to make the opening a bit wider. If that doesn't work, then move up one drill size. You want the front of the stylus to poke out enough to be usable, but not so much that it falls right out of the marker. Also, if you apply a little force to the end of the stylus as you push it through, it will make for a nice snug fit. Once you are sure of the fit, you can hit the tip of the plastic housing with a little sandpaper just to clean up the edge - use a very fine grit for this.
Step 5: Add the Glue
Once the stylus is perfectly fit into the plastic housing, it's time to glue it all together. First do a dry run - put the whole thing together and screw it down snug, to make sure everything fits as intended. If it's all good, then carefully squeeze out some hot glue into the opening of the metal housing (trying not to get any glue in the threads or on the opening). I used about two full "trigger pulls" worth of glue, but you may need more or less depending on your glue gun - you want to fill about 1/2" up from the bottom of the marker. Now at this point the metal housing will get pretty hot, so it's a good idea to use gloves, at least for the hand holding the metal. Once the glue is inside, quickly insert the plastic housing and screw it in tight. You may want to slowly rotate the pen (as if stirring a chemistry beaker) so the glue gets all around the edges.
Step 6: Let It Cool
Once it's cool, you're done!
Step 7: Enjoy!
You now have a nicely weighted stylus for your new tablet! When it's not in use, I put mine on a horizontal "mustache rest" designed for a smart phone, but anything will do....I'm sure you can find a solution right here that works for you. Best of luck!
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