The glue procedure is a little different than what you are visualizing. All of the pieces are a press fit and are inserted into the framework. The framework itself is a single wooden tube that has cutouts that are shaped identical (as much as possible) to the inlays and is about 1/10" longer than the brass tube. The brass tube itself is inserted without glue and centered up end to end in the blank. The blank is then flooded with thin CA on the joint lines of the outer surface. The thin CA works its way into crack and also the area between the brass tube and wood. Accelerator is not used and the glue is allowed to dry . After that it's pretty much business as usual. I trim the ends on a sanding disc on the lathe using a right angle jig to hold the tube perpendicular to the disc. I usually use a skew to turn them down to shape. There's really not much wood to remove. When designing the inlays I make the outer diameter of the blank about 1/4" larger than the through hole. That way you're only cutting wood that is 1/8" thick at most.
Scott, I sell inlaid and puzzle piece blanks now. I don't have an official, most of my sales have been via Facebook messaging. I'm currently in the process of working with a pen part supplier in Tennessee that will be carrying my kits on his website. I can't name the supplier at this time, but will try to update when the blanks become available there.
Brian, I'm sorry I don't do many videos or pictures of the process. I stay quite busy just keeping up with blank orders. I pretty much do the inlays like any of the others that do them. If you visualize the surface of a pen tube as 2" tall by X width that is equal to length of a pen tube, that is your canvas to lay out your patterns. Once laid out, you first cut the tube that has the framework to hold the inlays. I use a solid piece of dark colored wood for this. The inlays themselves are cut from the same design drawings, with the exception that they are over-sized by the amount of "laser kerf". Because of this over-sizing I don't get 2 complete complementary colored copies of loosely fitting inlays. I, however, do get inlays that fit snugly and won't fall out. I hope that this brief description helps.
Scott, I haven't done any Majestic or Majestic Jr. kits yet. I can do most of the designs I make on any pen type that has a tube that is equal to or greater than 3/8". I have done puzzles for the Jr Gent II series and adapting the drawings to Majestic Jr. wouldn't be that difficult because they have the same diameter tubes, I believe. Here's the latest puzzle design that I made the other day. This one fits Sierra tubes but could be adapted to other formats. What's different about it is the pieces are diagonal. I'm not sure I'm the first to try this, but I haven't seen it anywhere else yet.
