Pen turning is hands-down the best first project for anyone new to woodturning. The blanks are small and cheap, the turning is straightforward, and at the end you’ve got a genuinely useful object that looks impressive. I’ve given away dozens of handmade pens over the years and they always get a great reaction.

Here’s how to turn your first pen from start to finish.

What You’ll Need

Beyond your lathe and basic turning tools, pen turning requires a few specific bits of kit:

• Pen kit - these come with the brass tubes, twist mechanism, clip, and end caps. Slimline pens are the simplest and cheapest, running about $3-5 each from turning suppliers.
• Pen mandrel - a shaft that holds the blank between centres on the lathe. Around $25-40.
• Bushings - these sit at each end of the blank and give you the exact diameter to turn to. They’re specific to each pen kit style.
• Barrel trimmer - a cutting tool that squares off the ends of the blank after gluing. About $15-20.
• Drill bit - matched to the brass tube diameter (usually 7mm for slimline kits).
• Pen press - for assembling the components. A basic one costs about $30, though you can get by with a vice and careful pressure.

All up, the startup cost for pen turning gear (beyond the lathe) is around $80-120.

Preparing the Blank

Pen blanks are small rectangular pieces of timber, usually about 20mm x 20mm x 130mm. You can buy them ready-cut from turning suppliers, or saw your own from offcuts. Interesting grain, burls, and spalted timber all make for spectacular pens.

Start by marking the centre of each end and drilling a hole through the length of the blank using a drill press or the lathe itself with a drill chuck in the tailstock. Take it slow and clear chips regularly to avoid the drill wandering.

Cut the blank in half - each half will become one barrel of the pen. Rough up the brass tubes with sandpaper, apply a thin coat of medium CA (super glue) or epoxy, and glue a tube into each blank half. Make sure the tubes are fully inserted and the glue is set before moving on.

Squaring the Ends

This step is important. Use the barrel trimmer to square off each end of the blank flush with the brass tube inside. The trimmer pilots into the tube and cuts the wood and glue cleanly. If the ends aren’t square, the finished pen will have gaps where the components meet.

Mounting on the Mandrel

Slide your blanks onto the pen mandrel with the bushings in place at each end and between the two blanks. Tighten the mandrel nut - firm but not overtight, as too much pressure can distort the mandrel and give you barrels that aren’t quite round.

Mount the mandrel between centres on the lathe. Set the tool rest close to the blank, check it spins freely, and you’re ready to turn.

Turning the Blank

Set the lathe to a moderate speed - around 2,000-2,500 RPM for pen blanks. Use a spindle gouge or skew chisel to carefully reduce the blank until it matches the diameter of the bushings. The bushings represent the finished size of the pen hardware, so turning the wood flush with them gives you a smooth transition from timber to metal.

Take light, controlled cuts. Pen blanks are small, and it’s easy to take off too much in one pass. Work along the full length, keeping the shape even. A very slight barrel shape (thicker in the middle) looks good on many pens, or you can keep them straight - it’s your call.

Sanding and Finishing

Sand through the grits with the lathe running. Start at 180 or 240 and work up to 400 or higher. Micro-mesh pads (available from pen turning suppliers) take the finish even further if you want a glass-like surface.

For a finish, CA glue makes an excellent, durable coating for pens. Apply thin coats with the lathe running at low speed, letting each coat dry before adding the next. Then sand back with micro-mesh and buff to a high shine. It’s tough, water-resistant, and looks professional.

Alternatively, a friction polish gives a quick, attractive finish. Apply with a cloth while the lathe spins, and it dries almost instantly.

Assembly

Remove the blanks from the mandrel. Use your pen press to push the twist mechanism into one barrel and the clip/cap assembly into the other. Press the two halves together and give the twist mechanism a test. If it clicks smoothly, you’re done.

Where to Go from Here

Once you’ve turned a few slimline pens, try other styles - cigar pens, rollerball kits, and fountain pen kits all offer more variety. Acrylic and resin blanks open up a whole other world of colour and pattern. There’s a massive community of pen turners online sharing ideas, and Team400 among other tech-focused groups have even explored how makers can build an online presence to showcase and sell their work.

The beauty of pen turning is that each one only takes about an hour, so you can experiment freely. Make a dozen, give them as gifts, and enjoy the compliments. It’s a brilliant entry point into the craft.