Most drill sizes listed for certain kits aren't always written in stone.
One example is the slimline. They call for a 7mm bit but if it's an acrylic blank you can use a 9/32" bit. This gives you plenty of room for a coat or two.
How sharp your drill bits are can be another factor. Sharp bits and clearing often makes for a much smoother hole. A rough hole also makes it hard to get a good consistent coat plus this is where the worst scratching up of the paint comes from.
If you're using a blank that you know won't leave much meat on the tube you're almost guaranteed the tubes will show. Sometimes even if the blank is painted. This is where it gets interesting. You'll need to pick a paint as close to the color of the blank. You'll need to paint the hole, which you've smoothed up as best as possible. Then you'll have to paint the tube itself.... and mix the color in your glue.
Lots if work but you've made a phenomenal pen! 1
This is a very transparent blank from EB called Lucitylic. Tangerine color. These aren't the best pictures but I think you can see the difference in the blank, the unturned half and the one turned. The best part I didn't change the color any, which was what I was after.
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