| Wooden pens are a great starter project for learning the
lathe on the Mark V. The finished pens make great gifts and are inexpensive to make.
First you cut two pieces of stock to approximately ½"
x ½" (or slightly larger) and 2 1/8" long. This can be done easily on your
bandsaw. Next find your center by drawing two diagonal lines on each blank. Now you are
ready to drill through each piece using a 7mm (555713) drill bit. It is more accurate to
use the horizontal boring feature on your Mark V, but you must use your fence as a back
stop with a piece of wood as a backer board. Reverse your mitre gauge and remove the hold
down clamp and use it as a centering point for drilling. Once you have centered the piece,
lock your mitre gauge in place with the tapered set screw in the center of the mitre bar.
Now direct the drill bit to the center, hold the blank firmly in place and drill each
blank out slowly to prevent burning.
Next, take the two tubes in each kit (55529) and rough them
up with sandpaper. Now you are ready to glue the tubes into the blanks-Cyanoacrylate is
recommended. (CA-02) Run a bead or two along the tubes (note: hold the tubes with your
L-shaped allen key as the glue will dry in seconds), and insert the tubes in to the blanks
To ensure that the ends of the blanks are flush with the
brass tubes, use your disk sander and sand slightly to flush the ends.
Now you are ready to turn your first pen. You will need a
Mandrel (517722) which you put in your drill chuck to hold the blank. The end on the
Mandrel is bored so it will line up to your live center (if using a dead center, lubricate
with soap). Put on a bushing and then one blank, insert the second bushing and the other
blank followed by the third bushing and tighten the nut. Turn the blank to the diameter of
the bushings using a round nose lathe chisel (555029). Take off very little each pass and
turn at approximately "R" speed. This will take about 10 minutes. The tool rest
should be parallel to the blanks and as close as possible. (There is a 4" Tool Rest
(555314) that will allow you to get closer to the piece)
When you have turned the blanks to the bushing diameter or
slightly larger, it is time to sand. The best way to sand is while it is still on the
mandrel. This way you can sand both pieces at the same time. Start with 220 grit and
progress to 400 grit.
To polish the wood, first take some sawdust and hold it
onto the blanks. This is called burnishing.
To finish use HUT WAX which is a two step process. (941930,
941931) Slow down your machine to "H" speed and gently glide the brown bar
across both blanks. Now speed your machine up again and with a soft cloth or paper towel,
melt the wax into the wood. Again, slow down your machine and apply the white bar to the
blanks. Speed up your machine again to melt this in. The white bar has a buffering
compound in it that will give you a gloss finish. Repeat this step 3 times.
The assembly is the easiest part. First you squeeze in
(using a vise or "Quick Grip" clamp) the mechanism to the indented ring
(approximately ¼") in the first blank, then on the other end of the same blank,
press in the tip. The second blank requires a top and clip pushed in. Push the clip onto
the top and squeeze the two pieces into the end of the blank. Next, put the pen refill and
the center ring in place, push the two blanks together and you have just made your first