Facet with a Twist

[Wmcullen]

I'm not sure if this process is right or wrong; unique or common. But it works for me and I want to share in case it's interesting.​

19: Facets with a Twist
last post: 18- Working Quickly

I wanted to make a faceted pen but disrupt the shape with an unexpected twist at the end.​

The Problem
Despite lots of experiments, the straight facet jig I use with my router table wouldn't adapt to this challenge. Similar to last time, I wanted to avoid new purchases and use the tools I already own, including a 3d printer.

Solution
(Not rocket surgery, just how I did it.)
I merged a few experiments with the design Dave posted earlier this month and Frankenstein-ed another approach... that works!

Here's how it works:
Step 1
Slide assembly to cut straight section of facet.

Step 2
When hexagonal block hits the red stop block, begin twisting right handle.

Step 3
As right handle twists, the screw-shaped plug continues to pull the blank along in a curved path.

Repeat for all 6 sides.

Summary
After tinkering with this for the past few weeks it was glorious to have the process work yesterday. I even completed a second pen.

3D file and Assembly
In case you're interested, the 3D print file is attached as a zipped *.obj called FacetTwist1.zip.
It contains these four pieces.

More complete assembly list:

Assembly Notes:
The two washers are crucial. They keep the Spiral plug from falling out of the Hexagonal Guide.
A Cylindrical Guide on the right allows the handle to revolve while twisting. The center hole lines up perfectly with the Hexagon Guide. However this requires an additional Back Spacer to keep everything perfect.
The Back Spacer and stop block were held in place with a little masking tape.

Big Thanks
Pierre's beautiful Urushi pen provided inspiration for the project. I was only trying to mimic a single detail of his exquisite pen and it provided a great deal of fun.
As I mentioned before, Dave's bandsaw jig provided a new approach right when I was starting to hit a brick wall. Thank you!

Thanks for looking
- Cullen

 

[eteska]

Outstanding. Thank you for the detailed write up.

 

[tomtedesco]

100% agree with above.

 

[magpens]

WOW !! . . That is ingenious !!

Is your middle name "Edison" ? ..... you seem to have a generous endowment of his inventiveness !! . .

 

[Bryguy]

Brilliant innovation!

 

[mark james]

Another home runs! There is some wonderful creativity bubbling up on IAP recently. Very excellent Cullen.

 

[Sly Dog]

Your innovations amaze me.

 

[Wmcullen]

Thanks all. You're very generous.
I'm obviously having a lot of fun and sharing these ideas is wonderfully satisfying.
I appreciate every bit of feedback a great deal!
More importantly, I've had more "gee-whiz" ideas in the months since joining IAP than in the previous few years of pen turning. The peer encouragement, honest critiques, and raw inspiration found in this group is an invaluable gift!
- Cullen

 

[Pierre---]

Great pens Cullen! Glad if one of mine was a source of inspiration.

 

[guitarchitect]

Very cool! How about the holy grail - a 1mm wood threading jig! It would need a router (mounted horizontally, like a pantorouter) and probably a setup similar to the lathe threading jigs that are out there... and custom router bits! but think of the possibilities!

 

[Wmcullen]

Oh boy that challenge makes my head hurt.
I really like 3D printing, but I'm always cognizant that the parts my PLA-based printer create are "cheap plastic."
Precision isn't really in its nature... at least in my (in) experience.
But even as I'm typing this... you got my wheels turning.
Thanks!