Dale,
I just tried to make my first jar opener (I've got to do 20) and I had a real problem getting the large post to go into the hole after I finished it. I had to drill deeper and the only way I could get it up high enough to line up with the hole was to have the spur on my brad point bit poke through the top. I used a pen blank and left as much as I could in the middle but it didn't seem to be enough.
Did you have any trouble getting the hardware put together? Did you drill the holes after you turned it?
Try using a standard type twist bit to finish the hole. It doesn't have that brad point that will poke through at the end.
Also, use a larger blank ... Some pen blanks come as 3/4 by 3/4 by 5 inches or so ... but certain blanks you can get are 1 inch square by 5 inches.
If you have access to your own local wood, you can make your blanks whatever size you wish, or you could invest in spindle blanks to cut down. I know that PSI offers spindle blanks as large as 2 x 2 x 12, which would be plenty large enough for 2 good sized handles.