77c63 puzzle inlay kit - woodcraft77c63 04/15/09 puzzle inlay kit product #149733, 149735, 149736...

Woodcraft, 406 Airport Industrial Park Road, P.O. Box 1686, Parkersburg, WV 26102-1686© 2009 by Woodcraft, LLC. “Helping You Make Wood Work” is a registered trademark of Woodcraft, LLC.

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Product #149733, 149735, 149736Puzzle Inlay KitFor Navigator/Sedona, Cigar/Ultra Cigar, Cambridge, Churchill, El Grande Pen Kits

Step 1:

Remove all puzzle pieces from the container and arrange the pieces as per included diagram. The puzzle pieces are conveniently numbered to correspond with the diagram. Please note that the diagram might look different from this illustration.

Step 2:

Take the brass tubes from your pen kit and prepare it as you would normally do. Cut a piece of 2 inch blue painters tape, long enough to go around each tube twice.

Step 3:

DO NOT USE any glue at this stage .Start placing the puzzle pieces on top of the shorter tube. Start with number 1 and complete the first row. Place the blue painters tape on the first row of puzzle pieces as per photo illustration.


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Step 4:

Place the second row of puzzle pieces, numbers 6 – 8 and roll the blue tape on to the second row and follow with third and fourth row until the puzzle is complete. Numbers 1 – 16 will be used to complete this step. When the last puzzle is in place roll the blue tape to cover the last row and make sure it is tight. Use a ¾ inch tape and roll it tight around the tube to make sure that all the pieces are snug and tight. Repeat the same process as above for the longer brass tube, numbers 17 – 32 will be used to complete this step

Step 5:

Remove the scuffed brass tubes from the assembled puzzles and use any familiar method to glue the brass tube into the assembled puzzle blanks. Thick CA glue or an epoxy works well and cures pretty fast. Make sure that you give the glue enough time to cure before you proceed with the next step.

Step 6:

DO NOT USE a barrel trimmer, it will tear the puzzle pieces off the ends of the puzzle blank. Remove all the masking tape and prepare to trim the ends of the barrels. Use a squaring jig to trim the ends of the barrel.

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Step 7:

Place the barrels with bushings on the mandrel and place in the lathe. Use 180 grit sandpaper to sand the barrel to the desired shape. While sanding place a couple of ( thin ) CA glue drops on the barrel, that would fill all the small gaps in between the puzzle pieces and ensure a great finish product. You may use a skew or wood file to perform this step, just ensure that your skew is very sharp to prevent unnecessary damage. Use progressively finer sandpaper until you are satisfied with the finish. Remember that you are working with a blank made of many pieces. Proceed with caution.

Step 8:

The barrel can now be finished with a finish of your choice. CA glue works well to fill any gaps and provides a great long lasting finish.

Step 9: Follow your pen kit’s instructions to assemble your new pen.

(See attached Puzzle Assembly Diagram)



Puzzle Assembly Diagram

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77c63 puzzle inlay kit - woodcraft77c63 04/15/09 puzzle inlay kit product #149733, 149735, 149736...

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