Cutting the Acrylic Blank

The acrylic blank is cut roughly square on the bandsaw.

Drilling the acrylic blank

A 15/32" barrel is drilled into the blank on the drill press

Prepping the brass barrel

The brass barrel insert is scored before being glued into the blank.

Rough sharpening the roughing gouge

A nice unhoned 50-degree angle is set into the 1" roughing gouge.

Roughing out the blank

The gouge is used to round the blank and knock off the corners created by the squaring bit.

Shaping the barrel

The desired shape begins to emerge.

Cutting details

The final details are cut into the blank.

Sanding the blank

Progressive grits (120, 160, 220, 320, 400, 600, 800, 1000 and 2000) bring the blank to a high gloss. A coating of carnuba will complete the finish.

Prior to assembly

The pen kit parts will be assembled with a custom designed hydraulic pen press.

Finished!

All pen parts fit as planned. The gentle taper matches the kit parts.

Finished!

This is a gift for the makers fiance'