MikePittman
Member
I made a segmented Churchill pen today and took pictures showing the process. Last time I made a segmented pen, I included one photo and many emailed me asking for pics of the entire process, so with the weather so bad out, I had the time to do it. I know the veteran pen turners here will find this boring, so please forgive me. This is for those of you who want to try it for yourself. I hope this helps.
Start out cutting your wood. For this pen, I cut slats about 1/8th inch thick.
Use CA to glue the slats together and clamp them. After the blank is dry you drill the hole for the brass tube. Here you see the blank all glued and ready for drilling. Now you need to make the blank extra long, about 10 inches or so, because you waste some of the wood when cutting the segments. Mark and drill as close the the center as possible as it helps the put the segments in line on the tube. You won't be able to drill all the way through the blank, but you will continue drilling after cutting segments off the blank.
Next, you cut the segments. I use a table saw, but if you don't have one, you can use a miter or band saw. The table saw is much easier as it cuts the segments nice and square, which is very important. Before cutting the blank, you should mark up two sides of the blank with a marker. This helps to put the segments back together with each side facing the right direction and with the side facing the top correctly. You decide how thick you want the segments. For this pen, I cut them about 1/4th inch thick.
Have the brass tube near you so you can stack the cut squares up in the order you cut them. This helps to cut the right amount. Stack them with the marked sides matching.
Lay the squares down in line, like the picture shows, with the bottom piece first in line. It goes on first.
Start with the bottom piece, the one closest to you, and put CA around the inside of the drilled hole. DO NOT get any CA on top of the piece or on the tube above where the piece goes or you will have a difficult time putting the next one on. Next, one at a time, put CA on the top of the piece you just glued on and add the second piece. Push the piece down on top of the first, making sure all the sides match, (which is why you mark the blank!), and quickly turn it slightly in place before the glue sets up.
Continue until you get both blanks done. They will look like this when done.
After drying and getting both ends prepared so the brass is flush, I belt sand the spiral corners down some to help turning them on the lathe.
Turn the blanks and finish them. I used a CA finish. Here is the finished pen. I hope this helps those of you who have wanted to try and make a pen like this. I'd be very interested in seeing your pens!
Start out cutting your wood. For this pen, I cut slats about 1/8th inch thick.
Use CA to glue the slats together and clamp them. After the blank is dry you drill the hole for the brass tube. Here you see the blank all glued and ready for drilling. Now you need to make the blank extra long, about 10 inches or so, because you waste some of the wood when cutting the segments. Mark and drill as close the the center as possible as it helps the put the segments in line on the tube. You won't be able to drill all the way through the blank, but you will continue drilling after cutting segments off the blank.
Next, you cut the segments. I use a table saw, but if you don't have one, you can use a miter or band saw. The table saw is much easier as it cuts the segments nice and square, which is very important. Before cutting the blank, you should mark up two sides of the blank with a marker. This helps to put the segments back together with each side facing the right direction and with the side facing the top correctly. You decide how thick you want the segments. For this pen, I cut them about 1/4th inch thick.
Have the brass tube near you so you can stack the cut squares up in the order you cut them. This helps to cut the right amount. Stack them with the marked sides matching.
Lay the squares down in line, like the picture shows, with the bottom piece first in line. It goes on first.
Start with the bottom piece, the one closest to you, and put CA around the inside of the drilled hole. DO NOT get any CA on top of the piece or on the tube above where the piece goes or you will have a difficult time putting the next one on. Next, one at a time, put CA on the top of the piece you just glued on and add the second piece. Push the piece down on top of the first, making sure all the sides match, (which is why you mark the blank!), and quickly turn it slightly in place before the glue sets up.
Continue until you get both blanks done. They will look like this when done.
After drying and getting both ends prepared so the brass is flush, I belt sand the spiral corners down some to help turning them on the lathe.
Turn the blanks and finish them. I used a CA finish. Here is the finished pen. I hope this helps those of you who have wanted to try and make a pen like this. I'd be very interested in seeing your pens!