Blank Preparation1. Drilltheblankswitha“V”drillbitataspeedof900to 1200RPM.

2. PolishtheBrassTubeswith220gritsandpapertoremove oxidationandroughenthetubes.Thiscanbedonebyhand orbychuckingtheminadrillpressorportablehanddrill.

3. PreparetogluewithmediumCA(cyanoacrylate)glueor two-partfastdryingepoxy.

4. ApplythegluetotheoutsideoftheLowerTubewithaliberal amountaroundthetubeendthatisinsertedfirst.Donot applygluetotheinsideoftheblank,asthiswillcausethe gluetogetinsidetheBrassTubeandruinthetube.

5. Insertthetubewithatwistingmotionintotheblankuntilthe tubeisequidistantbetweenbothendsoftheblank.Wipeoff anyexcessglueontheendsoftheblank.Allowtheglue todry.6. Method 1:ApplythegluetotheoutsideoftheUpperTube withaliberalamountaroundthetubeendthatisinserted first.InserttheUpperTubeintotheendoftheblankcutto

17⁄8"long.Beginfromtheendthatwillbecomethecenter ofthepen,whereyouhavemarkedyour“x”forgrain orientation.Pushinthetubeuntilitisflushwiththetopend oftheCap,oppositetheentrypoint.Therewillbeaportion oftheUpperTubeexposedfortheCenterBand.Wipeoff anyexcessglueontheendsoftheblankandallowthe gluetodry. Method 2:GluetheUpperTubeintotheblankusingthe sameprocessastheLowerTube.

7. Usingabarreltrimmer,disk,orbeltsander,trimtheends oftheblanksuntilyoucanjustseethebrightbrassends ofthetubes.Thefacesoftheendsmustbeperpendicular totheBrassTubesandparallelwitheachother.Itis imperativetomatchthelengthofthetrimmedblankstothe originallengthoftheBrassTubesandthattheinsidesofthe BrassTubesarecleanandfreeofanyglue.

Turning the Blanks1. Assembletheblanksonthemandrelwiththebushings placedasshowninthepictureabove.Keepthegrain orientationoftheblanksinlinewhenmounting.Each bushinghasastepthatisdesignedtobeinsertedintothe BrassTubesforstabilitywhileturning,astheinnerdiameter ofthetubesislargerthanthemandrel.

2. Tightenthetailstockandthentightenthemandrelnutthat holdstheblanks.Donotover-tightenthetailstockormandrel nutasthismaycausethemandreltoflex,causingtheblank togooutofround.

3. Turntheblankstothedesiredshape,makingsurethatthe surfacesnexttothebushingsareturnedtothesame diameterasthebushings. Method 2:Turnoffthelathe.Measure17⁄8"fromtheCap endoftheUpperTubeandmakeadefinitivemark.Usinga sharppartingtool,removeallofthewoodfromthe17⁄8"

marktotheoppositeendoftheblank(approximately1/4" ofwood).BeverycarefulnottodamagetheBrassTube. Ifyouhaveadditionalturningorpolishing,stopthelatheand installthefifthbushingovertheexposedbrassperthe originalMethod1instructions.

4. Afterturning,sandthesurfacesinprogressivestepsof 220,400,600,and1000grit.Ifahigherfinishisdesired, micromeshsandpapermaybeused.

5. Applythefinishofchoiceandpolish.

6. Removetheblanksfromthemandrel,keepingtheblank orientationandgrainpatternsinline.

Gold Plateau Rollerball Pen Preparation and Turning

44079

© Rockler Companies Inc. 2011

Method 1CuttheLowerBlankabout1/8"longerthantheBrassTubetoallowfor“blow-out”orholeelongation.CuttheUpperBlanktoexactly17⁄8"long.ThiswillleavepartoftheBrassTubeexposed.Maintaingrainorientationofthetwoblanksforturningbyplacingan“x”oneithersideofthecutline.

Method 2Cuttheblanksabout1/8"longerthantheBrassTubestoallowfor“blow-out”orholeelongation.Maintaingrainorientationofthetwoblanksforturningbyplacingan“x”oneithersideofthecutline.Later,youwillneedtoturnaportionofthewoodblankdowntotheBrassTubeonthelathe.

Upper Tube NutMandrel “B” Lower Tube

Plateau FT/RB Bushing Set

12.4 mm 12.4 mm 11.5 mm 11.5 mm

Visit Rockler.com for the most current product information and videos or call 1-800-260-9663.

AssemblyReadtheassemblyinstructionscompletelybeforeassembly.

1. SlidetheDecorativeRingsontotheCenterBandasshown inthediagramaboveandpresstheassemblyontothe exposedbrassoftheUpperTube.Ifloose,carefullyglue intoplacewithasmallamountofCA(cyanoacrylate)glue.

2. UnscrewtheCapCouplerfromtheCapandpressitintothe otherendoftheUpperTube.

3. InsertthethreadedstudoftheCapthroughtheClipand threadtheassemblyintotheCapCoupler.

4. PresstheTipCouplerintotheLowerTube.Makesureyou choosetheappropriateendofthetubetopreservethe patternorgrainmatchforyourpen.

5. PressCenterCouplerintoopenendofLowerTube.

6. PresstheBlackTubeontotheCenterCoupler.

7. GentlypresstheLowerCapintotheopenendoftheBlack Tube.DonotpresstheLowerCapintoohard,oritwill spreadouttheBlackTubeandruinthefit.

8. InserttheSpring,largeendfirst,intotheTipCoupler.Insert theInkCartridge,thenthreadtheTipintotheTipCoupler.

Reordering Information Stock #GoldPlateauRollerballPenKit............................440797mmMandrel“A”with#2MorseTaper...............43537#1MorseTaperAdapter(requires43537)...........270507.35mmMandrel“B”(requires43537).................28652PlateauFT/RBBushingSet(requires28652)......46495“V”DrillBit............................................................39630

Gold Plateau Rollerball Pen Assembly

Clip Cap

Tip Ink Cartridge

Upper Tube

Cap Coupler

Lower Tube

Center Band

Decorative Ring 2

Decorative Ring 1

Tip Coupler

Center Coupler

Black Tube

Spring

Lower Cap

44079 - Rev 10/11

WARN

ING: T

his product contains one or m

ore chem

icals, including lead, that are know

n to the State of C

alifornia to cause cancer and birth defects or other reproductive harm

. W

ash hands after handling.

Made in C

hina

Distributed by R

ockler C

ompanies Inc.

© 2011 R

ockler Woodw

orking and H

ardware

4407

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