1 The first step in creating the pen is to prepare a blank, a rectangular piece of wood that will be filed and shaped into the two halves of the pen barrel. Virtually any type of wood can be used. However, it must be dry when the process begins. Colorful woods with interesting patterns are preferable because they make for a more attractive finished product. To prepare the blank, the wood is first cut into a rectangle approximately 0.75 in 2 × 5 in long (1.9 cm 2 × 12.7 cm).
2 Then, the blank is marked with a line (called a match mark) extending about 1 in (2.5 cm) beyond where a cut will be made separating the blank into two halves, an upper and a lower. The blanks are then crosscut into lengths that are slightly longer than the brass tube that will eventually be inserted into them. One way for the crosscut to be made is with a bandsaw equipped with a miter gage and an auxiliary slip fence, which is an adjustable fence especially made for cutting different lengths of pen blanks.
3 The blanks are then held in place using a jaw clamp or some other similar method, and a hole is drilled down the center of each half of the blank in preparation for the insertion of the brass tube. Each blank section is held in place with the match marks facing up.
Inserting the brass tube
4 Once the holes are drilled, polyurethane glue is applied to both the outside of the brass tube and the inside of each drilled hole. Then, the tube is inserted into the blank using a rotating motion to distribute the glue evenly. After approximately 10 minutes, the glue is usually dry and the tube stays securely in place.
5 With the pen secured, the tube is trimmed to fit precisely in the blank using an adapter sleeve and a barrel trimmer until a brass curl is produced.
Mounting and turning the blank
6 Once the tube is inserted, the upper and lower blanks are ready for mounting on a mandrel in preparation for turning. A split mandrel system, consisting of two short steel mandrels, is generally used. Each blank is mounted separately on the split mandrel along with the appropriate bushings.
7 As each blank spins, the wood that does not belong on the pen is carefully cut away using a gouge or similar tool. Finishing cuts are made using a skew chisel.
8 A notch is carved around the upper blank, completely through to the tube, using a thin parting tool. This notch is where a metal trim ring will later be inserted.
Sanding and finishing
9 Now the blanks have turned into pen barrels, ready for sanding and finishing. Sandpaper, starting with 120-grit and progressing to 180-grit, 220-grit, and finally 320- or 400-grit, is used to ensure a smooth finish. If Dymondwood is used, a grit as fine as 600 may be necessary for a high gloss finish.
10 The pen barrels are coated with a wax Vo r plastic polish, applied with a soft cloth while the barrels are still spinning.
Preparing for assembly
11 Prior to assembly, the sharp corners on each end of the finished barrels are sanded slightly.
12 If a clip is to be used, a notch is cut in the upper barrel in preparation for its insertion. To avoid chipping the wood, a grinding wheel or a file is used to cut this notch.
Clips, fittings, and bands
13 The clips and metal fittings used on fountain pens are stamped, just as when the fountain pen was first produced. Bands and overlays are rolled from sheet metal and hard soldered.
Final assembly
14 Now the ring, clip, and other metal trimmings are attached to the finished barrels to make a completed pen. A drill press and press jig may be used to press the pen parts together. The drill press is used as a vice, while the jig (a long, flat piece of wood with metal posts sticking up) is used to keep the parts in line during assembly. First, a nib coupler is pressed into the large end of the lower barrel. Then the lower barrel is flipped over, and an end cap is pressed into the smaller end. The nib is then inserted into the nib coupler.
15 Next, the trim ring and clip assembly are inserted into the previously created notches in the upper barrel. Then a closing cap is screwed in place using a cap adjuster tool or Phillips screwdriver to complete the assembly of the upper barrel.
16 Finally, the two barrels are screwed together and the fit is tested and adjusted with the cap adjuster or screwdriver if necessary.
Read more: http://www.madehow.com/Volume-7/Fountain-Pen.html#ixzz4Ox351PPr