Making a Wood Mallet - Router Forums
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post #1 of 30 (permalink) Old 12-03-2015, 05:23 PM Thread Starter
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Default Making a Wood Mallet



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.

Herb
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Last edited by Cricket; 12-04-2015 at 09:38 AM.
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post #2 of 30 (permalink) Old 12-03-2015, 05:30 PM
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Very Nice! I love making mallets!

"It's just a hardened oz or two of metal, sharpened to a razor edge, spinning at 24,000 rpm.....what could go wrong?"
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post #3 of 30 (permalink) Old 12-03-2015, 06:05 PM
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You never cease to amaze me Herb. That's a hammer worthy of Thor
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post #4 of 30 (permalink) Old 12-03-2015, 07:27 PM
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excellent Herb...
and the handle idea is great...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
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post #5 of 30 (permalink) Old 12-03-2015, 07:44 PM
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Great result....

Also like the detail on the handle...

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post #6 of 30 (permalink) Old 12-03-2015, 08:59 PM
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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?
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post #7 of 30 (permalink) Old 12-03-2015, 10:16 PM
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That's very nice Herb, but mine's BIGGER
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post #8 of 30 (permalink) Old 12-03-2015, 11:05 PM Thread Starter
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Quote:
Originally Posted by DonkeyHody View Post
That's very nice Herb, but mine's BIGGER
Holy Moly, DId you used to work for the circus and drive the ground stakes for the tents?

Herb
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post #9 of 30 (permalink) Old 12-03-2015, 11:10 PM Thread Starter
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Quote:
Originally Posted by FreeTime View Post
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.
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post #10 of 30 (permalink) Old 12-03-2015, 11:30 PM
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Quote:
Originally Posted by DonkeyHody View Post
That's very nice Herb, but mine's BIGGER
I want the best of them both!
I love the working end of Herb's but I like the size of yours, Hody.
So I will be lengthening the handle, and probably enlarging the head with a more wedge shaped bottom, to use as a noodle pounder...

Simply too kewl for skool...
~M
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