3500 pens in a single order from an virtually unknown turner is not being ordered by someone expecting each one to be a collectors item.
Exactly my point, Leroy... one simply doesn't purchase that quantity of anything and consider it art. You are purchasing a large number of items that look the same as every other one in the group, and each one will look (hopefully) like the sample that was given.
But my point is it is YOUR work and not someone elses they are coming back to or at least I would think you would want it that way. What is the sense of getting into pen making if you are selling someone elses work. I understand custom blanks but at least you turned it and finished it. Maybe I am missing something in this whole thing and not only your statement but the whole premise of this contract. If I am selling my work I do not want someone elses name on it. I will sink or swim with what I make. Forgive me if I am misreading you.
Let's separate the two ideas. People come back to me for the reason I mentioned above... they like what I offer them, both from a uniqueness standpoint and a quality standpoint. The same as the Martha Stewart items mentioned above... high quality (sort of) and unique (compared to other manufacturers). Beyond that is irrelevant.
If I only offer them a couple of similar pens, it's a hobby decision. If I offer them 3,500, it's a business decision. I enjoy turning a few pens. I enjoy the money from manufacturing 3,500 pens. If the two paths cross, awesome... but either way I get some enjoyment out of it (from either standing at the lathe creating one pen, or standing in line at the bank enjoying fat cash in my hand from 3,500 pens).
On to Egg's OP. While I cannot offer any suggestions for people, if it were
me, here's what I would do... set up a jig.
1) Cut 1' lengths of blanks (or whatever length is convenient).
2) Drill the blanks with a long bit. If it's more convenient or accurate to use shorter blanks and a shorter bit, do it.
3) Set up a jig to run them with a router. Use a quarter round bit... dirt cheap, so buy a bunch. The router gets them down to within, say, 20 mils of desired. Turn blank 90 degrees, run again. Bits exist to do a half-round, see if you can find the right size at a good price, cut the work in half.
4) Insert 1'-long tube using epoxy.
5) Sand entire blank to proper dims to 320grit.
6) Cut to length using fine-tooth saw. Sand ends, if necessary. Round edges so larger-than-kit ends do not protrude sharply and feel bad. Kits that have same dimension of blank feel fine.
7) Select and use an easy-to-apply finish, maybe something that polymerizes without extra work.
8) Do final sanding.
9) Assemble kits.
I may have left out a step or two that makes the flow a little better, but you get the idea.
This project is perfectly doable,
if you're willing to put in the time to create a good workflow and the proper jigs from the beginning. It will not be a half-day affair to properly create the jigs. Once done, however, it will make large orders that much easier in the future.
I would
not take the job if you also work an 8-5 or they are expecting the pens in a month's time frame. They must be reasonable in their needs, and you must be reasonable in your offerings.
