How are the pens made?

Acrylic or polyester resin is poured into a mold and set in a pressure chamber at about 80psi to get rid of any bubbles in the finish.

The acrylic is then drilled and brass tubes are glued inside, these brass tubes provide an inner surface for the other components to press into and stops the acrylic from cracking when i press them together (usually!).

Once the tubes are glued in place, i trim the ends of the acrylic to be flush and square with the ends of the brass tubes, for this i use a gadget that i made on my metal lathe.

Once square, I put the part on the wood lathe between centers and turn it down to the rough size/shape that i want.

From here, i use abrasive paper to take the pen down to final dimensions, frequently checking with the calipers to make sure i don't go too far.

Once the part is the right size, i start on the sanding and polishing process which is the longest part of the process. I move up through 120, 180, 240, 320, 400, 600, 800, 1200, 1500, 1800, 2400, 3200, 3600, 4000, 6000, 8000 and finally 12000 grit then move on to liquid buffing compounds and wax.

With the resin pens, the finish stops here since the resin is more durable than any other finish i can put on over the top.

For timber or composite pens, i now apply 20 coats of polyurethane lacquer or cyanoacrylate to give a hard finish and then once that has cured, move back to the sanding/buffing steps. Now that one half is done (usually the cap first) i start the whole process again for the pen barrel.

Pen Blanks

Rough Turned

Drilled and Cut

Glued and Trimmed

Polished and Finished