Making a Segmented Pen Using Corian

To make this pen I have used Red and White Corian, each piece is roughly around 150mm in length and 12mm square. I have also used black plastic in between the Corian when I began to glue up.


These blanks were bought as you see then; the plastic is cut to fit the width of two pieces of corian when glued together, once all the pieces are glued using medium CA, it looks like this.


Once the glue has dried it is time to cut the block in half, this is so it can be drilled to fit a 7mm brass tube.


Now is the time to use the sander and square the blank the best you can ready for the drilling. To drill the hole I do this on the lathe as I find that I get much better results cantering the hole.


Now using the bandsaw I cut the blanks into squares, these can vary depending on what type of pen you are making, I roughly use between 4 and 6 millimetres as my minimum and maximum.


Once I have cut the squares I run both sides over a piece of sandpaper just taking off any bits of corian from the cutting. Then using turps I clean both edges of the squares ready for gluing. Also I make sure that I run the brass tube through each hole making sure that they are free of the plastic …

On this occasion I have built up the squares off-set rather than them being level in alternate colours.


Once each blank is built up I place them in the vice and wait for the glue to go off before I sand off the edges ready for turning …


I leave the blanks to dry over night before I begin to work on them. The first thing I do once dried is get rid of some excess corian, either by the bandsaw like this one (below) or by sanding.



After I have finished turning the pen I then sand from 240, up to 400. Next I use micro mesh wet and finish it with two coats of Hut Gloss Plastic Finish …


The picture in not to good as it was getting late when I took the picture, you can see the shadows from the trees in the background.

Downloadable PDF Below ...

Thats a good tutorial Jim, and a nice pen. When i turn corian i only place one blank on the rod as i get a lot of wobble with two on it do you know why?

Not sure Andy without actually seeing the issue? Thou it could be that your mandrel is bent, or you don't have it tight. Can't see any other reason why it should bounce.

That's a fantastic tutorial, Jim. Thanks a ton for it. I'm going to try it with some wood blanks and will use 0.5mm ally for the sandwich. Will put up pics once done.

David

yes it is nice and i look forward to seeing it in wood also.

Jimjam66 said:

That's a fantastic tutorial, Jim. Thanks a ton for it. I'm going to try it with some wood blanks and will use 0.5mm ally for the sandwich. Will put up pics once done.

David

Click to expand...

Your welcome David, i hope it helps you with future pens, look forward to seeing your segmented pen.

Jim, with your Slimline pens, I really like the slightly larger barrels with the tiny taper on the upper end of the lower barrel to make the center band and upper barrel stand out slightly.
Now a dumb question. On the plastic center bands, Do you glue the plastic on the end of the upper barrel to turn it as one piece or make the plastic center bands as a separate piece? Also, what is the source (type) of material you use for center bands?

Thanks Old Corky

Hi Corky, thanks for the comment, This band is glued onto the wood and drilled before turning, the resin or wood center bands i use are added after the blank is semi turned. The plastic that i use is called styrene sheets which are used by model railway enthusiasts ...

Hi the wobbly mandrel is probably because of too much pressure from the tail stock.

Love the pen Jim and the tutorial!!!!!!!!

Great tutorial ..something to get my teeth into when I get more proficient ..:up:

edlea said:

Great tutorial ..something to get my teeth into when I get more proficient ..:up:

Click to expand...

Thanks Ed, that day will come quicker than you think ... :wink:

I bought my first bandsaw this weekend after getting frustrated with performance and safety of my other cutting options in my first few pens so interesting to see an advanced technique made to look straightforward as I start on pen making. I think this could also be a great way to use up multiple tiny scraps of wood and make a Multi origin pen. I keep a box of these scraps and generally use them to start the log burner in the winter. I'm not sure how bad any small gaps would look so guess accuracy in cutting and sanding must be doubly important. I definitely will try this in a few weeks time - a few other projects and work trips first.

Davideccroft said:

I'm not sure how bad any small gaps would look so guess accuracy in cutting and sanding must be doubly important.

Click to expand...

David, the glue line will show much more if you don't cut the slabs square ... Those scraps of wood you have laying about the shed make super pens ...

Jim said:

David, the glue line will show much more if you don't cut the slabs square ... Those scraps of wood you have laying about the shed make super pens ...

Click to expand...

David don't believe Jim he fills his gaps with loads of sawdust and CA!!!!!!! lol

Jim said:

Thanks Ed, that day will come quicker than you think ... :wink:

Click to expand...

It only took Jim 55years!!!!!! lol

Hello Jim:

Very nice and clear instruction. My first lesson in making segmented pen blanks from corian materials. I have friends in Interior design business and they agrees to give me all the scrap or leftover whenever they used it. My problem is that these scrap is mostly very big in size.

Once again thank you very much

Edward Po

Love the Tutorial Jim,
Between you and Doug I have been stuck to everything today in my garage, trying my first brick effect segmentation - bloody CA...
Have to go around with a chisel tomorrow and release everything from my benchtop 'again'

Edward Po said:

Hello Jim:

Very nice and clear instruction. My first lesson in making segmented pen blanks from corian materials. I have friends in Interior design business and they agrees to give me all the scrap or leftover whenever they used it. My problem is that these scrap is mostly very big in size.

Once again thank you very much



Edward Po

Click to expand...

Edward you could always ship it over to us ....

Nice pen must try that