You want me to reveal all of my secrets???
OK. Here is the way I have been doing these.

On the screw-cap pen, I insert the regular threaded plug into the end
of the brass tube and then cut a slot through the brass tube for the
clip below the plug BEFORE the tube is glued into the wood. A blind
hole is drilled into the pen blank so the assembly will bottom out.
After the glue is dry, I turn and sand the barrel, then cut a
matching slot through the wood and fit the clip. I grind the round
mounting tab on the clip back so it is a rectangular tab with the
hole in it. When the pen is finished the clip is slipped through the
slot and secured with a screw from the bottom.

I take a cut across the center-band to remove the plating and reduce
its diamater by about 0.030". This also gives the glue something to
bite into. Then it is buried under the trim material at the bottom of
the cap.

There are two ways to make the snap-cap. One is to do the same thing
as described for the screw-cap pen, except that I put a stud into the
bushing and hold the clip in place with a thin nut. This gives me a
stud inside of the barrel to hold the Nylon cup. It is a very secure
way to hold the clip.

The other way to assemble the snap-cap is to recess the end of the
brass tube about 3/8" from the finished end of the wood. Then a slot
is cut just above the clip bushing, the clip is ground to shape, and
then it is held in place with a screw from the top. The plug for the
recess is turned from the adjacent piece of wood, so there is usually
a very good grain match. It is easier to match the grain than it is
to use another way to attach the clip. I have been using a
contrasting material in the top end of some of the pens, and this is
the easier way of doing it when I will have to be making a plug
anyway.

I prefer to make these pens with the snap-cap because I can eliminate
the center-band, and then I can get the shape I want.

So far, I have been using the stock clips. I have made a couple from
silver flat stock, but it will take a few more caps before I am ready
to show these to anyone.

And I will send bigger photo files next time.

Russ Fairfield
http://www.woodturnerruss.com/