This is a simple project that requires some router work and gives you a useful tool as an end product.
It requires 5 pieces to build.
The diam of the head is 4 3/4" long,3 1/2" high, and 2 1/4" wide. this requires 4 pieces
The handle it 13" long X 3/4" thick,and tapes from top to bottom 1 1/2"-1 5/16".
I made a jig so that when the head is built the hole will fit the taper of the handle.
While the head was glued up and waiting for the glue to dry, I made the template to route the contour of the handle.
When the head was ready I cut the face at a 5 degree angle and installed the handle from the top down and drove some wedges into the top of the handle. Then cut off the extra wedges flush to the top of the head and sand the handle flush.
I finished the mallet with a coat of sanding sealer, a coat of shellac, and 2 coats of water based acrylic.
Like the hammer ... I made one similar and actually named it Thor. (but I see you made enough for the whole Norse army or all the elves at the north pole with spares, coming up with enough names is going to be problematic). I like your dimensions better - think mine is a little too big. I tapered the handle to fit a matching taper in the hammer and skipped the wedges. Glued some leather to one face. I have a fix the "too nice to use" problem - skip the furniture grade finish . Is it too late to join that club?
Since it was a Christmas present, I wanted to doll it up. But the members did mention that too.
If you are in our area you are welcome to join,but only the members that attend the meetings get a present. Every year I do this ,make something for them.
Herb
Paul,
I did cut the wedges and wedge slots on the band saw.
WARNING: I SHOULD MENTION HERE THAT BEGINNERS SHOULD NOT TRY TO ROUND THE END OF THE HANDLE TO SHAPE THE CURVE ON THE ROUTER. GO TO THE DISK OR BELT SANDER FOR THAT. GOING AROUND THE END TO RADIUS THE EDGE IS OK BUT UNLESS YOU ARE VERY EXPERIENCED, ROUTING AROUND END GRAIN IS DANGEROUS.:no::no::no:
Thanks for all the compliments, glad you enjoyed this thread.
Nice looking tool Herb, just my sense worth two cents may be the mallet might strike with an oomph if the head were to be heavier.
I suggest some extra weight in the cavities made in two small center pieces next to the handle.(depending on what it's being used for)
Great way to make a mallet Herb.
From a previous post of yours I made a collection of mallets using left over pcs of hardwood.
Over a time I have given them to family and friends, they loved them.
Now you have jogged my memory I looked in my off cut box.
Next project is making more mallets.
Thanks Herb
Cheers
John T
If you texture the ends, you have a meat tenderizer. Maple, edible oil finish. This is one of those historical threads well worth resurection, just in time for Christmas.
That really is a beautiful mallet. I'm too lazy to go to that trouble so this pdf shows how I made a one piece one which I have used quite a lot.
Your photo-shoot is perfect, more members should consider doing the same.
Wow, that is a cool way to make one, that material is harder than maple. I like the angle too, some mallets have too much angle to the face,less is better I think.
Herb
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