From your selected pen kit, remove the brass tube(s) so you know how long to cut your pen blank. Lay the brass tube (or tubes for a two-barreled pen) against the blank and measure 1/16" to 1/4" longer than the tube to allow a little extra "working" material while you drill and barrel trim.


Cut the blank(s) where you marked your designated length. With a pencil or marker, draw an "X" corner-to-corner on one end of your blank to indicate the center point of the blank’s end.


Use a medium drill speed to drill the blank(s). Raise the bit from the blank every 1/4" to 1/2" to allow the chips to clear from the flutes of the drill bit. Don’t force the drill bit; use an even pressure and let the bit do the work. Slow up your drilling pressure as you near the bottom of your blank so you don’t "blow out" the bottom of the blank.


After drilling your blank(s), use a small piece of 80-grit sandpaper and prep your brass tube(s) by sanding the tube’s exterior to roughen its surface. Sanding the tube will give your glue a better grip on the inside of your blank as the brass is generally manufactured with an oily, smooth surface. Apply medium CA glue to your brass tube before inserting the tube into the drilled blank.


Barrel trimming is an important last step in preparing your pen blank as it "squares up" your pen blank at the ends and readies it for the lathe. Trim until you see the shiny top edge of the tube and that your blank material is completely flush with your tube’s end. If even the slightest edge of blank material remains around the top rim of the tube, your pen will not fit together properly when pressed together. Repeat this trimming process for each end of the blank.

Download Comprehensive PDF