Toolmate | Churchill Pen Kit Fountain Silver

TMT Churchill Pen Kit Fountain Silver (Pen Kit Only) 

Instructions

Tools Required

• Pen Mandrel
• Mandrel Saver Tailstock Live Centre (Optional)
• Churchill Bushing Set
• 11,7mm Drill Bit
• 13,25mm Drill Bit
• Pen Assembly Press (Optional)

Cutting and drilling the blanks

• Cut each blank 5mm longer than the brass tube
• Drill a hole through the centre of the blank
• Either use a drill press with the blank secured in a vice or clamp or use your lathe with a drill bit mounted into the tailstock chuck
• Drill at high speed penetrating about 10mm to 20mm at a time and then clearing the swarf to prevent overheating of the drill bit
• To prevent cracking or chipping of the wood when the drill bit exits the other end of the blank, stop drilling 3mm before the drill bit reaches the end of the blank and then trim the end of the blank using a saw to expose the hole

Glue the brass tubes into the blanks

• Using 200 grit sandpaper, lightly scuff the exterior of the brass tubes to prepare them for gluing
• Apply a thin layer of superglue or epoxy to the tube and insert the tube into the blank
• Rotate the tube as you push it into the blank to spread the glue evenly – this must be done fairly quickly to avoid getting the barrel stuck before it’s inside the blank
• Position the tube inside the blank so that the wood extends beyond the tube on both ends to allow for trimming

Trimming the blanks

• Square the ends of the wood blank with the tube using a disc sander
• Alternatively, fasten the blank into the chuck and trim the barrel carefully using a parting tool

Mandrel setup and turning

• Assemble the bushings and the blanks onto the mandrel as shown in the diagram below
• Ensure that the mandrel is tight on your lathe using the mandrel saver tailstock live centre or your live centre in the dimpled end of the mandrel
• Do not over-tighten the tailstock or mandrel nut as this may cause the mandrel to flex resulting in off-centre barrels
• An alternative is to use a mandrel saver tool to tighten the blank into the lathe without putting strain on the mandrel shaft
• Turn the blanks to the desired shape leaving the blanks slightly larger than the bushings
• After turning, sand the blanks using progressively finer sandpaper until the desired finish is reached

General assembly points

• Use a pen assembly press or vice/clamp with wood/plastic jaws to prevent damage to the parts during assembly

Pen assembly

Layout the parts as shown below

• Press the end cap into the smaller end of the long tube
• Remove the nib from the coupler and press the unthreaded end of the nib coupler into the larger end of the long tube

Fountain Pen

• Attach the ink cartridge to the back of the fountain nib
• Thread the fountain nib into the nib coupler
• Slide the clip onto the cap, then press them into the short tube
• Press the centre band coupler into the other end of the short tube to complete the pen

Operating the pen

• Always keep the cap on when not in use to prevent the ink from drying
• When using the pen, screw the cap over the body end