PSI Woodworking PRODUCTS PKL02 7mm Letter Opener Kit Instruction Manual
- June 13, 2024
- PSI Woodworking Products
Table of Contents
PSI Woodworking PRODUCTS PKL02 7mm Letter Opener Kit Instruction Manual
Model PKLO & PKL027 mm Letter Opener Kit Assembly Instructions
Features
Overall length : PKLO = 5-3/4 inches PKLO2 = 6-3/4 inches
Step 1 • Cut Wood Blank
You may use any thickness from 5/8″ to 1″ square stock, cut blanks to the
length of the tube plus 1/8″. Grain should run lengthwise.
Step 2 • Drlll the Wood Blank
Drill a centered hole lengthwise through your blank. Excessive pressure will
cause the drill bit to wander and/or split the blank. Slow the feed rate and
back the bit out repeatedly for chip removal. For best results you can use a 7
mm twist drill bit or brad point drill bit (7 mm=.2756 dia.). If not
available, use a 9/32 (.2812 dia.) bit – although slightly larger than the 7
mm bit, you will get acceptable results.
Step 3 – Glue the tube into the blank
Use epoxy or a gap filling cyanoacrylate (super glue), to glue the tube into
the blank. Coat the outside of the tube, then insert into the blank with a
twisting motion to spread the glue until flush. Allow it to dry.
Step 4 – Square the ends
With a barrel trimmer, disc or other sanding device, square the ends of the
blank 90 degrees to the ends of the brass tube as needed.
Step 5 – Turn the wood blank
Install the blank on a turning mandrel with a bushing against each end.
Tighten the nut snugly and bring the tailstock center firmly against the end
of the mandrel.
Tum the handle to any shape that will give you the appearance desired.
Step 6- Sand
As with any sanding, progress through a range of grits. The type of wood used
and the quality of the beginning surface will dictate your selection.
- 80-100 grit if rough surface or additional shaping is needed (overly thick)
- 120-150 grit if fairly smooth and straight
- 220-240 grit for final finish with most domestic woods
- 320-400 grit especially on dense or oily exotic woods
Scotch Brite® works well and doesn’t tend to scratch. Sand with blank spinning. Do your final sanding with the grain and the lathe off.
Step 7 – Finish
Try a finish of your choice but be careful if brushing on a poly, etc., you
could stick the tube, bushings, and mandrel together. The following friction
polish works well on most woods.
1/3 wood alcohol (methanol), 1/3 white/clear shellac, 1/3 boiled linseed oil.
Mix equal parts of the three ingredients in a bottle and shake before using. Apply with a rag to the spinning tube. Apply two coats. Remove the tube from the mandrel.
Step 8 – Touch up
If necessary, a light sanding of the handle ends on a block will square them
and improve the fit during assembly.
Fabrication aids
Drill bits, mandrels and bushings are available from your supplier. PKLO uses
standard 7mm bushings, and PLKO2 uses PKMONT-BUSHINGS.
Assembly PKLO
a) Line up end cap, sleeve (wood tube) and threaded coupling.
b) Press components (above) together gently with your vise.
c) Screw letter opener blade into coupling.
Assembly PKL02
a) Line up the two retainers with the sleeve (wood tube), making sure
that the chamfered ends are against the sleeve.
b) Press the components gently with a vise.
c) Screw cap into one end of the sleeve and the blade into the other end.
d) A drop of glue may be applied to all mating parts to ensure a
permanent joint.
© 1995
PSI Woodworking Products, Caroline and Comly Roads, Philadelphia, PA
19154 rev04/22