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Gold Plateau Pencil Preparation and Turning

© Rockler Companies Inc. 2014

Blank Preparation1. Cut the blanks about 1/8" longer than the Brass Tubes to allow for “blow-out” or hole elongation. Maintain grain orientation of the two blanks for turning by placing an “x” on either side of the cut line.2. Drill the blanks with an “O” drill bit at a speed of 900 to 1200 RPM.3. Polish the Brass Tubes with 220 grit sandpaper to remove oxidation and roughen the Tubes for better adhesion. This can be done by hand or by chucking them in a drill press or portable hand drill.4. Prepare to glue with medium CA (cyanoacrylate) glue or two-part fast drying epoxy.5. Apply the glue to the outside of one Brass Tube with a liberal amount around the end that is inserted first. Do not apply glue to the inside

of the blank, as this will cause the glue to get inside the Brass Tube and ruin it. 6. Insert the Brass Tube with a twisting motion into the blank until the Tube is equidistant between both ends of the blank. Wipe off any excess glue on the ends of the blank. Allow the glue to dry. Glue the second Brass Tube using the same method.7. Using a barrel trimmer, disk, or belt sander, trim the ends of the blanks until you can just see the bright brass ends of the Tubes. The faces of the ends must be perpendicular to the Brass Tubes and parallel with each other. It is imperative to match the length of the trimmed blanks to the original length of the Brass Tubes and that the insides of the Brass Tubes are clean and free of any glue.

Turning the Blanks1. Assemble the blanks on the mandrel with the bushings placed as shown for Setup Part 1 above. Keep the grain orientation of the blanks in line when mounting. Each bushing has a step that is designed to be inserted into the Brass Tubes for stability while turning, as the inner diameter of the tubes is larger than the mandrel. Note: The Center Band may be taped onto the Stepped Bushing and used to test the fit of the turned tenon and the Lower blank.2. At least 3/8" (9.5mm) of the Upper blank closest to the Stepped Bushing at the center of the pen must be turned to a 12.7mm diameter to match the outer diameter of the Center Ring.3. An 1/16" portion of the Lower blank closest to the Stepped Bushing must be turned to a diameter that will fit loosely inside the Center Band (approximately 10.1mm). It may be helpful to stop the lathe occasionally to test the fit. Make sure the Center Band has been resecured before turning the lathe back on.4. Stop the lathe and reassemble the blanks on the mandrel with the bushings placed as shown for Setup Part 2 above. Keep the grain orientation of the blanks in line when mounting. The rounded edge of the Center Band should remain oriented toward the Nut of the Mandrel. The Center Band should be secured before the lathe is turned on.

5. Turn a tenon on the end of the Upper Tube nearest the Stepped Bushing to match the inside diameter of the Center Band. Tenon length should be 11/32" (8.7mm) and tenon diameter should be 13/32" (10.3mm). Take this cut a little at a time so that you do not cut the tenon too small. Stop the lathe occasionally to test the fit with the Center Band by trying to slide it over the tenon. The fit should be snug. Make sure the Center Band has been resecured before turning the lathe back on. The portion of the Upper blank nearest the Stepped Bushing should be turned to the diameter of the Center Band (approximately 13.6mm). Once the tenon has been cut, this fit can be verified with the Center Band.

6. Turn the remaining portions of the blanks to the desired shape, making sure the surfaces next to the end bushings are turned to the same diameter as the bushings.7. After turning, sand the surfaces in progressive steps of 220, 400, 600, and 1000 grit. If a higher finish is desired, micromesh sandpaper may be used.8. Apply the finish of choice and polish.9. Remove the blanks from the mandrel, keeping the blank orientation and grain patterns in line.

Upper Tube NutMandrel “A”

Plateau Bushing Set

Lower Tube

12.4 mm 12.4 mm 10.1 mm 10.1 mm

Center Band

Wood Spacer

Mandrel “A” Setup Part 1:Tenon Section

NutMandrel “A”

Plateau Bushing Set

12.4 mm 10.1 mm 12.4 mm 10.1 mm

Wood Spacer

Mandrel “A” Setup Part 2:Upper Tube Lower TubeCenter BandTenon Section

Gold Plateau Pencil Assembly

Clip Cap

TipPencil Mechanism

Upper TubeLower Tube

Tip Ring

Black Tip

Cap Coupler

Center Band

48716 - Rev 07/14

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. W

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Made in C

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Distributed by R

ockler C

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© 2014 R

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AssemblyRead the assembly instructions completely before assembly.1. Press the Center Band onto the tenon cut on the Upper Tube during the turning process. If the Center Band is a little loose, it can be glued into place with a small drop of CA (cyanoacrylate) glue. 2. Press the Cap Coupler, chamfered end first, into the other end of the Upper Tube until the shoulder is flush with the blank.3. Insert the threaded stud of the Cap through the Clip and thread the assembly into the Cap Coupler. 4. Slide the Tip Ring onto the Black Tip and press the Tip assembly into the end of the Lower Tube that is not fitted to the Upper Tube.

5. Insert the Pencil Mechanism, threaded end first, into the Lower Tube until it stops. 6. Thread the Tip onto the Pencil Mechanism to lock it into place. 7. Slide the Pencil Cap (Upper Tube assembly) over the Pencil Mechanism and turn clockwise until lead appears. To refill the Pencil Mechanism, turn the Pencil Cap clockwise as far as it will go in order to clear the mechanism of old lead particles. After the mechanism is cleared, rotate the mechanism counter-clockwise and insert lead. Keep turning until about 1/8" of lead is exposed, then gently press in the exposed lead. Lead size is 0.9mm.

Reordering Information Stock #Gold Plateau Pencil Kit . . . . . . . . . . . . . . . . . . . . . . . 487167mm Mandrel “A” with #2 Morse Taper . . . . . . . . . . 435377mm Mandrel “A” with #1 Morse Taper . . . . . . . . . . 39389Adjustable 7mm Mandrel “A” with #2 Morse Taper . . . . . . . . . . . . . . . . . . . . . . . . . 25581Plateau Bushing Set . . . . . . . . . . . . . . . . . . . . . . . . . 44937“O” Drill Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20074Pen Mill Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47526