This Cigar Pen and Pencil Assembly Guide is written with the Rotur kits in mind but can be used as a general guide for most types of kits.
- 7mm Drill Bit.
- 9/16″ x 9/16″ x5″ Pen Blank.
- Pen Mandrel.
- Slimline Bushings.
- Glue (Thick CA or Epoxy).
- Drill or Drill Press
- Barrel Trimmer/Disc Sander.
- Pen Press or Clamp.
- Eye and Ear Protection.
Cutting and Drilling the Pen Blank
- Draw a 1″ line lengthwise across the centre of the blank to help maintain proper grain alignment when turning.
- Cut each blank 1/4″ longer than the brass tube.
- Using a drill press with the blank secured in a vice or clamp, drill a hole through the centre of the blank stopping an 1/8″ short of the bit exiting the blank. Drill at 2,000 to 3,000 rpm, backing the drill bit partially out of the hole every 1/2″ to clear debris. When using larger bits or drilling plastics drill at 250 to 500 rpm.
- Trim away a small amount of wood from the end of the blank to expose the hole. The blank should be slightly longer than the brass tube. This technique prevents cracking caused when the bit exits the blank.
Glueing the Brass Tubes into the Blanks
- Lightly scuff the exterior of the brass tube with 220 grit sandpaper to prepare it for gluing.
- For a fast bond, use thick cyanoacrylate adhesive (super glue) or 5 minute epoxy. For additional working time and a stronger bond, use expanding polyurethane (Gorilla or Sumo Glue). Apply a thin layer of glue to the tube and inside the wood blank. Insert the tube into the blank rotating it as you go to ensure the glue is spread evenly. Position the brass tube in the blank so that the wood extends beyond the tube on both ends to allow for trimming.
Trimming/Truing the Blanks
- Square the ends of the wood blank with the tube using either a barrel trimmer or disc sander. This step is critical for the pen components to fit together properly. DO NOT trim the brass tube as this may result in an improper fit when the pen is assembled.
Mandrel Setup and Turning
- Assemble the bushings and blanks on the pen mandrel as shown below. Be sure that the ends of the blanks with the reference mark meet together at the centre of the mandrel.
- Advance a 60° revolving cone centre into the dimpled end of the mandrel and tighten using light pressure. Do not over tighten the tailstock or mandrel nut as this may cause the mandrel to flex resulting in off centre barrels.
- Turn both blanks to the desired shape leaving the blanks slightly larger than the bushings.
- Sand the blanks using gradually finer grits of sandpaper and then apply the finish.
Assemble the Parts
- Layout the parts as shown paying careful attention to keep the pen tubes in the same orientation as when on the mandrel. Use a vice or clamp with wood or plastic jaws to prevent damaging parts during assembly.
- Hint: While removing the tubes from the mandrel, mark the inside of each brass tube where they join to maintain grain alignment during assembly.
- Press the writing tip into the end of the lower tube.
- Press the twist mechanism, brass end first, into the opposite end of the same tube until the chrome section meets the end of the tube. Install the refill and actuate the twist mechanism to determine how far the refill point extends beyond the writing tip. If necessary, press the twist mechanism slightly further into the brass tube to expose more refill. Be careful not to press the twist mechanism too far into the tube as it cannot be pulled out.
- Slide the clip onto the stepped portion of the cap. this will only slide part way on so do not attempt to force it.
- Press the clip/cap assembly into the end of the upper tube.
- Slide the centre band over the twist mechanism.
- Slide the upper tube over the exposed twist mechanism to complete the pen.