Making A Pen Case

[Anne-Sophie]

Is there anything you cannot do Michael?

 

Those boxes are heirloom pieces.

[my63]

Thanks Anne-Sophie, My intention is that the boxes will last at least one generation

 

No time to rest though there are still cases to make. First up is the five pen Emperor case.

I have made five pen cases before just not in this size

 

Starting with the flat sheet Kydex which I heated and formed over the ne mold I have made, My usual Emperor molds have the clip orientated on the horizontal axis. This mold has the clip in the vertical which will reduce the overall width of the case, By around 25mm and will add 5mm to the overall height of the case.

 

2021-11-07_05-52-12 by my0771, on Flickr

 

After molding the Kydex needs to be trimmed to the correct size, this is not as easy as it looks

 

2021-11-07_05-53-09 by my0771, on Flickr

 

Once the pieces are all equal it is time to wrap them in suede.

 

2021-11-07_05-53-49 by my0771, on Flickr

 

Wrapping complete.

 

2021-11-07_06-06-40 by my0771, on Flickr

 

After I completed wrapping what I call the insert, I was able to take the measurements I needed to make the form for the front panel.

 

2021-11-07_06-08-03 by my0771, on Flickr

 

This needs some sanding before I can do a trial pressing with leather.

  

 

 

[Anne-Sophie]

I know about Kydex, I have some items made of it, it is extremely strong.

 That you can trim it is a mystery to me

 

The more pictures you post, the more elaborate your process looks.

 

Your cases will be treasured for many decades to come!

 

 

[my63]

Thanks Anne-Sophie, Kydex is indeed a tricky product to work with especially when you apply heat, I have to get the Kydex hot enough to form around my mold. Once it has cooled it will retain this shape and is as you mentioned very hard.

 

Because I used MDF to make the form for the wet leather, I applied some paint to seal the MDF from moisture. The MDF I used for the upper part of the form is moisture resistant MDF.

After spending the night in the clamps the leather now looks like this.

 

 2021-11-10_07-00-48 by my0771, on Flickr

 

Dye will be applied next  

[my63]

Once I was happy with the shape of the front cover, I applied the first coats of black dye.

 

2021-11-13_06-48-59 by my0771, on Flickr

 

After three coats I was happy with the colour so it was time to bring the components together.

 

20211113_143220 by my0771, on Flickr

 

While waiting for the pieces to dry I started making a pair of small pen cases for John @ St John's pens.

Starting with flat Kydex sheet which I heat and mold using pressure and a wooden form.

 

20211112_130209 by my0771, on Flickr

 

This creates what I call an insert the Kydex piece wrapped in suede.

 

20211112_130415 by my0771, on Flickr

 

A piece of wet veg tanned leather is then molded over a larger form again pressure is applied. As the leather dries out it retains the shape.

 

20211112_130617 by my0771, on Flickr

 

After applying some navy blue dye I bring the components together gluing them in place. 

 

20211113_132329 by my0771, on Flickr

 

Stitching is next.

[Anne-Sophie]

So you always apply dye after forming the leather, that makes sense because the form needs to be made from wet leather, with the templates, with enough time to dry.

 

So when you said "I had to redo the stitching" did you have to redo everything from the kydex insert to the suede wrapping and the leather forming?

[my63]

I always dye the leather after forming it wet, I usually apply the dye before it dries out fully. When the leather is formed it stretches under the pressure. This would alter the colour requiring more dye. I have found it easier to wet both pieces form the front, then apply the dye to both pieces side by side counting the coats to keep the colour as close as possible.

I am a bit obsessive about stitching, I cut out stitching for many reasons. Often I stitch too early before the dye has dried fully and the thread picks up dye. I prefer to stitch with one piece of thread, Saddle stitch has a needle on each end of the thread as you stitch it forms a knot inside the leather. If a thread ever snaps, (not likely) you will only lose one stitch. If I used a machine and a thread snapped it would unravel. 

Thread choice is also important, I use a linen thread Lin Cable made in France it is very expensive £25 for a 50grs reel 

When you are stitching there is a front and a back side obviousley. It is very difficult to get them both right. the needles have to pass in the exactly the right place almost like a figure of eight as they pass throught the leather.

 

 2021-11-14_09-10-29 by my0771, on Flickr

 

I dont look at the front of my stitching anymore. The back is more important, If you ever see a leatherworker looking at someone elses work they will always look at the back.

[Anne-Sophie]

Such a work of art!

 

I love to hear about your techniques, sooo impressive!

[my63]

The pair of blue cases are finished and have been shipped to my friend John at St Johns pens this is the last picture I have.

 

2021-11-18_07-58-43 by my0771, on Flickr

 

This is the stitching in progress picture of the 5 pen Emperor pen case.

 

2021-11-18_07-59-41 by my0771, on Flickr

 

Final finished pictures 

 

2021-11-18_08-00-15 by my0771, on Flickr

 

2021-11-18_08-00-29 by my0771, on Flickr

 

Another case finished and ready to ship.

[Anne-Sophie]

People in the U.K, run to St John Pens to get the case and a matching pen.

 

Bonus 1: no need to fight the "bargain for the latest gadget or toy" shoppers.

 

Bonus 2: give a heirloom gift.

 

Mike, gorgeous work, as usual.

[my63]

Thanks Anne-Sophie, I am pleased to say I have almost caught up on my orderbook. In fact this is the final case in my current book. 

As ever it started with flat sheet kydex which has been molded into the shape for this case. I am often asked if I make cases for normal pens, the answer of course is yes I do  This case is designed for pens that are 15mm maximum in diameter.

 

 

 

 

Outer cover is next.

[Anne-Sophie]

I am amazed at the pace of your work!

[my63]

Thanks Anne-Sophie.

It has taken me a little longer to catch up than I thought, After this I am back to a four week waiting time. Currently there are 10 cases in the book. And a huge project to carry 80 to 100 fountain pens.

 

Back to the three pen case for smaller pens, I have made good progress today I have dyed the outer covers and glued all of the components together in preperation for stitching.

 

2021-11-21_05-56-18 by my0771, on Flickr

 

I have marked an cut the template to mark out the stitching of the flap. I will make the marks for the stitching tomorrow.

 

 

[Anne-Sophie]

1 hour ago, my63 said:

Back to the three pen case for smaller pens, I have made good progress today I have dyed the outer covers and glued all of the components together in preperation for stitching.

 

1 hour ago, my63 said:

I have marked an cut the template to mark out the stitching of the flap. I will make the marks for the stitching tomorrow.

 

I believe it is the first time, I have seen the steps of production for each pen case, in order of completion.

 

Mighty impressive! I now understand your frustration more, and need to have a stitching template. At the beginning of the bespoke pen case projects, you had to redo some of the stitching, so now you have templates.

 

Sorry I called you Mike, instead of Michael. It was very late across the pond. 

[my63]

Dont worry about the name Anne-Sophie I have used all of the vairiations at some point in my life, I have been called a lot worse

 

Stitching leather is not as straightforward as it sounds, needles do not make the holes special hole punches make the holes some are called pricking irons they just make a mark in the leather and an awl is used to go the rest of the way through. My hands dont like awl work so I use a stitching chisel which makes a hole all of the way through the leather. I will add some pictures later when it stops rainig, That might be next week or next year  

 

I have tried many ways of marking out the flap, The normal way is to make the flap and use a pair of dividers to mark a stitching line inside of the outer edge, This method does work but I found it caused issues.

 

2021-11-21_09-34-25 by my0771, on Flickr

 

Actually taking this picture made me realise this template was too long so I have shortened it since I took this picture.

 

2021-11-21_09-34-25 by my0771, on Flickr

 

This is not straightforward the thickness of the case location of the strap and lots of other things have to be considered.

[Anne-Sophie]

 

I remember when you were using the awls, at the very beginning before you had the operations.

 

You said that you were getting new items when you made your workshop but I think you only shared the leather stamping machine. 

Since the horrible virus showed up soon after, I didn't want to ask more about the workshop, out of respect because of your dedication to your fellow countrymen and your loss.

 

I also think you caught the virus, which made me very nervous and I was just waiting for you to come back on the forum and was very happy when you came back.

 

Now, if you could share some photos of your workshop, I would be very happy.

 

 

 

 

[my63]

Workshop this is a tricky one, I designed it to have two side benches and a work table at the back. This did not work for me so I removed the wide table from the back.

This is my woodworking bench. The top is removable.

 

2019-12-31_08-01-48 by my0771, on Flickr

 

This is the leatherworking side. The gray bench now runs the full length. The woodworking side now has a bandsaw and sanders on wheels.

 

2020-01-13_09-06-34 by my0771, on Flickr

 

2020-09-19_09-35-56 by my0771, on Flickr

 

All of the walls have french cleats so drying racks can be placed anywhere, In fact everything can be mounted on the cleats and moved where it is needed.

 

2020-03-28_05-10-45 by my0771, on Flickr

 

The workshop now sits on this deck with its huge 12 ft mitre which was not as easy as it looks  

 

2019-10-25_10-43-46 by my0771, on Flickr

 

The inside pictures are all old as I had to move tools from a small shed that was leaking. So It is a mess in there.

 

This is the current stae of the outside I plan to paint it before the end of the year.

 

2021-11-23_08-39-37 by my0771, on Flickr

 

Unfortunately Due to health challanges and other commitments I have struggled to do most things, I bought myself a new tool for joining timber called a Domino jointer. I planned to use this to finish the inside of the workshop but also for the upcoming kitchen and utility room builds I have planned.

 

2021-05-22_10-33-50 by my0771, on Flickr

 

My health has improved a little since the coronavirus I am currently being tested for long covid. I did spend many months working on a bid for a government contract to make PPE but was not successful.

 

 

 

[Anne-Sophie]

The pictures are very impressive, I saw the little garden shed that was there before, so everything is brand new.

 

8 hours ago, my63 said:

The workshop now sits on this deck with its huge 12 ft mitre which was not as easy as it looks  

 

I had to search the other meanings of the word mitre because, I thought, why does he need a 12 foot bishop hat, in a workshop?

 

Mitre box, a tool for guiding a saw to make mitre cuts

Mitre saw, a saw for making mitre joint

Mitre square, a tool for marking and checking angles

 

Which one of those 3 is it?

 

8 hours ago, my63 said:

8 hours ago, my63 said:

 

 I did spend many months working on a bid for a government contract to make PPE but was not successful.

 

In order to be successful to get one of those, it is more important for someone to have connections, than manufacturing knowledge, crumbling walls or polluting disposable PPE from overseas, has made someone wealthy. 

 

8 hours ago, my63 said:

Unfortunately Due to health challanges and other commitments I have struggled to do most things, I bought myself a new tool for joining timber called a Domino jointer. I planned to use this to finish the inside of the workshop but also for the upcoming kitchen and utility room builds I have planned.

 

I am extremely impressed about your accomplishments, especially pen cases, boxes, briefcases, which you continued to produce in the face of both covid and your hands challenges.

 

I was worried when you said you were sick and was delighted when you posted again.

 

 

"A domino joint is actually a mortise and tenon joint", I didn't know anything about the name, domino,  but I am familiar with  mortise and tenon joints, which are used in traditional furniture making.

As a matter of fact, I became a stickler for finding those, in order to authenticate a piece of furniture as an handmade artisan piece, not a machined reproductions.

At the time, my family was in the process of furnishing the living room and bought reproductions, which I found overpriced. I told them so in the showroom of the interior designer, who was making drapes, obviously with a high standard of craftsmanship, since they are really beautiful, even many years later. She was not amused, so I was given "a look", but, she could not deny that they were reproductions.

 

 

8 hours ago, my63 said:

My health has improved a little since the coronavirus I am currently being tested for long covid.

 

I just heard in the news from Europe that many with long covid cases have a sustained immunity.

 

In my area, in the U.S, we never stopped the surge because there are a lot of people who refuse both the vaccine and mask wearing. As a result, the irresponsible variant makers, get expensive helico rides to local hospitals, where they seek expensive treatment and clog the ER capabilities, all that on my dime, since they are not charged for any of it.

 

As a result, since the beginning of the pandemic, I am only outside masked, in long sleeves and pants, even in extremely hot weather, for grocery shopping and items pick ups,  from small businesses, where everyone is masked and vaccinated, which need all the help they can get.   

 

 

[my63]

Sorry that was not very clear al all.

The miter joint refers to the decking boards which had to be cut at 45 degrees I think there were 48 of them in total.

I did not have the right connections to get one of the contracts that is very much the situation.

My breathing is still causing issues along with the fatigue I have had blood tests today so should have news by the end of the week.

The Domino machine makes what they call loose tenons or rather it creates the slots for the tenons in each piece and the tenons can be made or bought. Of course I bought the machine just as the price of plywood and other sheet materials hit a record high. I am not going to make high end furniture just yet but this machine will even make boxes easier to make.

 

Back in the pen case world I have started stitching the components together.

 

2021-11-23_06-55-41 by my0771, on Flickr

[Anne-Sophie]

I didn't mean to be confusing or annoying about your previous post.

 

The pen case is lovely! Beautiful colors pair.