Penlight Project Kit Instructions
Penlight Kits Assembly Instructions
3 pcs.bushing set penlight bushings
12.5mm drill bit
universal squaring jig or a 7mm barrel trimmer with a trimming sleeve
2 part epoxy glue or Insta Cure(cyanoacrylate) glue
2*2*13CM long blank
Preparing the blanks
Cut the blanks to the size of the brass tube (add 1/16” for trimming)
Drill .492 (12.5mm) hole, through each blank.
Glue each tube in the blank. Insert with a twisting motion to spread the glue evenly inside the blank.
When the glue dries,use a universal squaring jig or a 7mm barrel trimmer with a trimming sleeve.
Trim the wood down,flush to the brass tube.
Turning the blanks
Mount the bushings and blanks on the mandrel according to Diagram “B” (end bushings are the same)
Turn the wood down, close the to size of the bushings. Sand the wood to the bushing diameter. Finish the wood with your choice of polish.
Assembly (See Diagram A)
Note: Layout finished parts acording to Diagram A
Insert the front band over the coupler, press the coupler into the upper barrel.
Press the center band into the opposite end of the upper barrel.
Press the lower barrel into center band.
Press the nut, recessed end in first into the opening at the lower barrel, press flush with the wood.
Screw the click mechanism, spring in first into the nut
Insert the clip over the exposed threads, slide the slotted band with the slot end in first. Align
Affix the plunger over the white stem. Thread the upper cap on. Be sure clip is seated in the slot.
Drop 2 AAA batteries, plus side up, into the opening at the front end.
Place the spring behind the bulb base, insert into bulb holder. Screw holder into front end of the Pen Light.
The Pen Light is ready to operate by clicking on and off on the plunger.