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Thread: REPLACEMENT ALUMINUM PENCIL SLEEVE

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    dave_rupp1's Tools

    REPLACEMENT ALUMINUM PENCIL SLEEVE

    Many years ago I was purchasing the Pentel P200 series of mechanical drafting pencils. They worked great until I started using them in construction while building my daughter's house. I was breaking the plastic sleeve regularly enough that I decided to fix the problem. I machined an aluminum sleeve to replace the plastic one and haven't broken one since.

    I also made a mandrel to hold the sleeve while machining the surface. This speeds the operation and achieves better accuracy.

    I fill the grooves in the sleeve with an acrylic paint that is color coded to the lead size in the pencil. Yellow is for 0.9mm, blue is for 0.7mm and black is for 0.5mm. These are the colors of the plastic sleeves on the original pencils. I also have one that is filled with red lead, therefore the grooves are red.

    After the sleeve is complete, I polish it and then coat it with a clear sealer to prevent oxidation.

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4299_01.jpg
    Starting with 3/8" aluminum stock, turn the end 0.236 x 0.052

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4300_02.jpg
    Drill a #21 bit 1" deep. Turn approx. 2 1/2 degree taper.

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4302_03.jpg
    Cut grooves for a better grip or just for looks. I used a 60 degree threading tool spaced every 0.080" x 0.020" deep.
    Reverse the sleeve and trim to length (4.440"). Drill 1/4" x 3.75", then drill #15 x 4.27" and finish with a 17/64" x 0.8" deep.

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4303_04.jpg
    Mandrel I built from 12L14 to hold pencil sleeve while finishing the outside.

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4308_06.jpg
    Turn down sleeve surface to 0.361 to eliminate imperfections in the surface. Turn pocket clip recess 0.80" from end, 0.015 deep by 1/4" long.

    REPLACEMENT ALUMINUM PENCIL SLEEVE-dscn4314_07.jpg
    The top yellow pencil survived building a house, the bottom two blues ones are brand new. I build them now to give as gifts.
    Attached Files Attached Files

  2. The Following 3 Users Say Thank You to dave_rupp1 For This Useful Post:

    Howder1951 (04-04-2020), Jon (04-03-2020), rgsparber (04-04-2020)

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    Looks like a great application for those kit pens that you make a wooden sleeve for, perfect for the mechanic or machinist type! Excellent!

  4. The Following User Says Thank You to Howder1951 For This Useful Post:

    dave_rupp1 (04-04-2020)

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    Thanks dave_rupp1! We've added your Mechanical Pencil Sleeve to our Miscellaneous category,
    as well as to your builder page: dave_rupp1's Homemade Tools. Your receipt:





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