Segmented Blank Assembly

I’ve learned a few tricks with the handful of segmented pens I have made. Here are a few ideas to keep in mind if this is something you are going to try.

In the first segmented pen I made I tried to rely on the (360 degrees / # of segments) / 2 formula to put together each segmentation layer. I have to admit my cuts on the segmented pieces are probably close to what they should be, but they are not right on. This variable causes gaps and slows down the assembly process.

What I’ve found to work the easiest is to assemble half of each segmented layer separately (picture 1). This allows me to then deal with just two segmented piece per layer. I sand the mating surface of each face flat to create the completed segment layer (picture 2).

(picture 1)

(picture 2)

Once I have all the layers completed, I begin constructing the pen blank. Each layer is glued to the growing blank and the top face is then sanded flat to prepare for the next layer (picture 3).

(picture 3)

The blue painter’s tape is used to keep the segmented pieces from sticking to the plywood work piece. A box knife seems to work well for popping the segmented piece off of the plywood.

-- ~ www.darrylmasterson.com ~ www.woodworkingdungeon.blogspot.com ~