Pens, Wine Bottle Stoppers & Miscellaneous
Last updated on Sunday, November 24, 2019 02:52:41 PM Mountain US Time Zone


Pen Body, Pens, Arbor Press, Wine Bottle Stoppers, Turner's Cube, Component Stand

The following photos illustrate how to use metal-cutting equipment & techniques to make wooden pen kits.
Always wear safety glasses & breathing protection especially when cutting & sanding Cocobolo.
Wood dust can be highly irritating to eyes & lungs or can even cause an adverse reaction.

Pen Body

Euro pen instructions. Automatic center punch used to eyeball the center for drilling.

After cutting the wood into two lengths, they are drilled with a 7mm Brad-point bit.

The brass inserts are lightly sanded to break the shine & then super glued into the Cocobolo blanks.
Insert & glue the brass tubes so that they are almost flush to the middle of the wood piece.
This minimizes the amount of wood removed by the counter bore thus keeping the grain continuous.

A reamer is used to counter bore down to the shinny edges of the brass inserts.
The brass is barely cut by the reamer. The reamer's pilot also removes any excess super glue.

A small zero-flute countersink is used to deburr the brass tubes.

With the original grain aligned the blanks are mounted onto the arbor with the spacers for a Euro pen kit.
Use of a live center is mandatory.

Cocobolo pen bodies being turned on the Jet 9x20 using a (OEM Taig) round-nose tool bit & power feed.

A 10.5mm diameter x 5mm long tenon was made using a cutoff tool bit.
Setting the lathe DRO to metric units made cutting the tenon quite easy.

 The wood has been waxed.

Claro Walnut (Northern California.)

The lathe's compound was used to cut the two different tapers.

Animation showing how the pen tip is pressed in using the bench vise. Aluminum jaws do not mar the parts.

The twist ink cartridge mechanism is inserted into the body using the arbor press.
It's an iterative process of press & test to make the ink cartridge tip protrude properly.
The assembly order is important so follow the instructions carefully.

Animation showing how the pen top is pressed in using the bench vise. Red Loctite secures the insert.
The cap is loose (screwed out 1/2 turn) so as to push the top plug slightly below the end's surface.
The top nut with the clip are then attached with some red Loctite.

Animation showing how the pen ring is pressed on using the bench vise.
I also super glue (gel-type) the ring.

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Aluminum, Corian & Cocobolo pens.

Arbor Press

1/2-ton arbor press used to assemble pens & other things.

Delrin, Teflon & brass faces for the working surfaces (ram & anvil) are interchangeable.
Softer surfaces eliminate/reduce damage to the part. The lower arbor plate can be removed for more clearance.

The mounting plate was modified to allow a two-position bolt-down to hard points on the bench.
It has six adjustable metal feet. The front of the press can hang over the bench edge for long parts.

 Wine Bottle Stoppers

Retro 1930s car knob shapes.

Used the ball turning accessory. Tagua (vegetable ivory) is easy to machine but often has internal cracks.

Left three are aluminum & the right two are stainless steel. Incorporated SS fender washers as shields.
The washer hole was too large (thus off-center) so there is a small, shallow collar turned onto the shank for centering.
The washers were burnished on the lathe at the same time as was the sphere. Blue Loctite secures the threads.
The stub is 1/2" dia. x 0.84" & the ends are chamfered 45 deg. Used the 5C collet depth stop for speed & consistency.

Low-profile stoppers: aluminum construction with SS 1/4-20 bolts & washers, silicon seal.

Reduced down to simply four parts with no threading: top disk, stopper core, a rivet, & the silicon seal.

Materials: Black Delrin (small) & black nylon (large), anti-corrosion SS washers, aluminum & silicon.

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Turner's Cube

A 2-inch square CNC-produced turner's cube using cocobolo.

Cocobolo block locked into the CNC mill vise.

Setting router bit's Z-depth for the Mach3 control software.

CNC mill cutting a series of circular pockets.

Component Stand

A component stand to raise a DVR 3" higher for better remote control LOS. The rubber feet fit into the tubes.
The rods are held to the tubes using 10-24 set screws in tapped holes but the last two attachments
required small access holes in the back so a hex wrench could be used to tighten the bolts.

Adapted audiophile component adjustable brass feet by modifying them to be a press-fit into the tubes.
One-inch anodized tubes with 3/4" ID. The component feet are 0.785" so the ID had to be bored out.

For this 10-24, I disconnected the fine down feed so the screw section could pull down
the spring-loaded quill lever. Mill turned at 110 RPM.
Always use
proper lubrication.





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Infrared (IR) photo of the Hub for the Logitech 950 universal, programmable remote.
I wanted to see the locations of the IR emitters. Looking closely, the clear, domed IR LEDs
can be seen: 1-left, 2-front, 1-right & 2 on top. It really blasts-out IR energy.
The very dark red (black looking) plastic housing is, of course, invisible to IR {nice}.
The unit's (2) wired remote IR units (not shown) have 3 LEDs each & put out quite a blast, too.
The 950 remote communicates with the Hub via RF not IR, thus not requiring line-of-sight operation. 

Pen Body, Pens, Arbor Press, Wine Bottle Stoppers, Turner's Cube, Component Stand