got in the shop last night and made a pen for my wife. This is just how I do it, everybody has their own way, and they're pretty much all different.

First you pick out the wood blank and the pen kit. I picked out a zebrawood blank, and a black titanium click gel writer kit.


Each kit comes with either one or two brass tubes. When there are two tubes, you decide how they'll line up once assembled. You'll want to remember how they go so the grain will match.


Then you cut them down to size, a little longer than the tubes. I use a bandsaw with a little sled. I'm planning on building a new sled that has an adjustable stop, and a clamp so I can keep my fingers away from the blade.


Blank cut down to size.


Then I use the lathe to drill a hole in the center. Some people use a drill press. I'm planning on buying a new drill press so I don't have to switch tools on the lathe as much. They say the lathe is more accurate though. I think it's just personal preference. You have to make sure the hole is centered though, otherwise it won't come out perfectly round and you'll have high spots when you put it all together.


The drilled hole where the brass tube will go.


You use cyanoacrylate adhesive (also known as super glue or CA glue) to glue the tube in the wood. You rough up the tube with some sandpaper first.


While the glue is drying, I prepare the lathe. Each pen kit has bushings that hold the wood in place, and tell you how thick you need the wood to be. The tubes slide onto a mandrel and the brass nut tightens it down. If it's too loose, the wood will just stop when you put the tool on it, and then you can't cut it.


Once the glue is dried and cured (I wait about 2-3 minutes), you get the ends flush with the tubes. I use a disc sander with another sled, some people use a pen mill which has a shaft that goes in the tube, and a cutter on the end. Another personal preference thing.