Custom Finial for a Navigator Pen

I recently got a request for a pen to be made with wood supplied by my customer.  He sent me a beautiful piece of Black Walnut and requested the pen show as much of the wood as possible.  I decided that replacing the finial with a custom wood finial would show off more of the  walnut.  The pen style he had chosen was the Navigator, but this technique can be used on many other pen styles.

The first step was to glue a piece of the walnut to a scrap mounted in a chuck.  You need to consider grain orientation at this point.  I chose to show the end grain on this finial, so the piece of walnut was aligned to the lathe, similar to how the body of the pen was turned.  For some woods though it may be better to align the finial perpendicular to the lathe, so that the side grain shows.  As well as the visual look of the two different grain orientations, bear in mind that end grain may accept the finish differently to how side grain will.

While the glue is drying, it’s time to break out the handy dandy Harbor Freight Transfer Punch Set.  This is one of those tools that until you get one you don’t realize how much you will use it.  Drill a 13/32″ hole in a scrap piece of wood.  The idea is the hole is larger than the black metal finial on the Navigator cap, but smaller than the actual cap.  Turn the cap upside down over the hole, select the appropriate size transfer punch and with a gentle whack with a hammer knock the black metal finial out.

With a pair of calipers, measure the diameter of the black metal finial and then turn the piece of walnut to that diameter, rounding the end of the walnut.  Apply the finish.  I used a CA finish here.

Using the calipers again, measure the diameter of the post of the black metal finial, and then turn a post on the walnut finial to the same diameter.

Sand the finish and then remove the chuck, scrap wood mounting block and custom finial from the lathe.  Carefully buff the finial.  Don’t get aggressive with the buffing, remember that skinny little post the finial is attached by!

Now that the finial is nice and shiny and your “inner magpie” is satisfied, mount the chuck back on the lathe and carefully part the piece off leaving a small length of the post.  This post helps to center the new finial on the cap.

A dry fit to make sure the custom finial is the correct size and the post fits nicely in the hole.

I use medium or thick CA Glue to attach the custom finial to the cap.  I like to apply the glue from the inside of the cap.  I find that if I apply the glue under the custom finial and then press it onto the cap, the glue squirts out from under the finial.  Although the bond is formed within minutes, leave the cap sitting upside down in a ventilated area for at least 24 hours.  This will allow the glue to “out gas” and prevent any tarnish forming on the finish of cap.

When assembling the pen, use the scrap block of wood with the 13/32″ hole in it.  That way the pressure from assembly is applied to the metal cap and not to the finish of the custom finial.  Side note:  No, I didn’t forget to add the clip   My customer requested the pen not have a clip.

The completed pen and a close up shot of the finial.

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