Thanks for nice comments. The error was that on the front of the pen, there is nice space between the cb and the end of the laminated piece but on the back I somehow overlapped the laminated piece with the top band, with no gap.[:I]
Ralph, If there is one thing I have learnt here it is that most of the pens that look tricky or difficult to make are actually quite simple. I cut my full blank freehand on the bandsaw to follow the grain. I then filed the bandsaw cuts as flat as I could. The black is from the base of throw away flower pots. The ally is just some scrap.
The ally was anodized and I have had previous failures with glue joints. This time, I sanded the anodizing off first and tested a trial joint. I could not break it. This could be a coincidence as I used new CA. I have read here that it can go off after a while.
Another trick is the use of black. I find that this is the best contrasting colour and as such, hides lots of small imperfections.[
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