I really enjoyed making this pen; I used the Rifle Cartridge Bullet Pen Kit from Rockler and a 1X1X3-inch cocobolo blank.
Preparing the blank
I didn’t have to cut the blank because it was already 3 inches. Securing the blank in a drilling jig I drilled a 10mm hole in the center. Cocobolo is a dark oily wood so I set my drill press speed to 600-rpm backing the bit out of the hole every 1/2" or so to clear chips. To prevent cracking or blowout when the bit exits the blank stop just before the bit exits the blank. Then trim the blank to 2 ¼" exposing the hole.
Sand the brass tube with 220-grit sandpaper to rough it up so the glue will stick. Using medium CA (cyanoacrylate) glue apply a liberal layer on the brass tube. Quickly inserted it into the blank with a twisting motion spreading the glue evenly and centering the tube in the blank. Note; if you don’t like CA glue or need more working time use 12-minute epoxy.
After the glue sets trim the blank using a barrel trimmer.
Note; do not trim away any brass tube as this may result in an improper fit when assembling the pen.
Turning the blank
The rifle cartridge bushings allow you to turn a 10mm pen blank on a 7mm mandrel. Assembling the mandrel start with 1 spacer then a 7mm brass tube another spacer riffle bushing pen blank 2nd rifle bushing. Do not over tighten the mandrel nut or the tailstock when mounting the mandrel as this can cause the mandrel to flex and the turning will be off center. When I first started turning pens, I wish I had known this little trick as my first pen had wood on one side and brass tube one the other.
You can shape this pen anyway you want. I chose to cut 3 beads, as they look good, show off the figure of the cocobolo and feels nice in the hand. I cut the blank down to the exact size of the bushing then sanded it to be slightly smaller. I then apply an acrylic finish that brings the diameter back to the size of the bushing.
Finishing the blank.
Sand the bare wood to 3000-grit and then apply the acrylic finish. Using thin CA and a paper towel apply a layer of glue on the blank while the lathe is turning and spray it with activator. I use the paper towel because if it catches it with just tear whereas a rag with wrap around the blank and possibly cause injuries. I put 5 coats of CA and then sand using 320-grit until the smooth. I do this 4 to 5 times for a total of 20 to 25 layers and then polish. I start with 320, and work through 400, 600, 800 &1200-grits, then because it is acrylic I use the micro mesh cushioned abrasives pads in grits: 1500, 1800, 2400, 3200, 3600, 4000, 6000, 8000 and 12000. Finally after the pads I use Novus Plastic Polish #2 Fine Scratch remover and get a mirror like shine. Since the finish is acrylic it lasts practically forever.
Now assemble the pen following the instructions that came with the kit. Press the threaded adapter in the large end of the shell casing then the bullet nib in the other end. Install the spring and ink cartridge into the cartridge then screw in the transmission mechanism. Press the decorative ring in one end of the blank then press the pen clip and finial in the other end. Put the two halves together and you now have a beautiful pen
