Roy's Mystery Mallet #2: Mallet - 1, Glen - 1

  • Advertise with us
Blog entry by pastorglen posted 03-10-2012 02:42 AM 4321 reads 2 times favorited 5 comments Add to Favorites Watch
« Part 1: Mallet - 1, Glen - 0 Part 2 of Roy's Mystery Mallet series Part 3: Dressed and Ready for Work »

Dear Saint Roy,

I like you a lot more this week. Lots.


Mallet Boy in PA

If you haven’t gotten a copy of the April 2012 issue of Popular Woodworking, do it today. That’s where this insanity all got started. But I’m telling you, I never could have launched into this if it weren’t for that article. They do a great job. Check them out.

The second attempt with the hardwood turned out to be much better. Doing a practice run with the poplar was a great idea and helped me figure out the angles and such.

As I wrote in the previous blog, I also used my marking knife for nearly every cut. When I couldn’t see the mark it was making, I used a fine-tip pen. That helped out, too. Using two dedicated marking gauges was also helpful. Same with the sliding t-bevel.

I’m pretty happy with the results.

The joints were much better, too.

Some things I learned:

1. Perfection doesn’t come the first time, and that’s okay. The second time is usually going to be better, so give your project a second attempt.
2. When I was cutting the sides of the mallet head, I used my chisel to cut a starter-groove for my saw. That helped create nice, crisp joints. A must for this project.
3. The hardwood (which I think is either oak or ash—it was a hand-me-down) was easier to work with than I expected.
4. I had my boys help me with the assembly. They were totally into it and excited with the results. More generational woodworking.
5. I test fit this and re-measured just about every way I knew possible. When I was ready to “bite the bullet,” I glued it up real good, and started assembly. YOU WILL NOT BELIEVE how hard I had to hit this to get it to go together. Even still, the fit is pretty much right on.
6. The only change I would make is in the assembly. As you can see from the detail of the top of the mallet head, there is some discoloration on the right side. I didn’t realize that my mallet head was bottomed out on the vise, and I sort of crushed the end grain on that side. Not a big deal, but I would be more careful about that if I were doing it again.

I’ll add some finish and include a closing picture later.

Thanks for looking in.

-- Glen, Pennsylvania, Colossians 3:23 "Whatever you do, work heartily, as for the Lord and not for men."

5 comments so far

View dpow's profile


504 posts in 4084 days

#1 posted 03-10-2012 05:11 AM

Looks good Glen. That should serve you well. Thanks for sharing .

-- Doug

View Tim Dahn's profile

Tim Dahn

1628 posts in 4805 days

#2 posted 03-10-2012 01:37 PM

Mallet boy you should be proud of this! Very nice, the “practice poplar ” one definitely helped you figure out the joints. looking forward to the pics with the finish on it, you will get many years of use out of it.

-- Good judgement comes from experience and experience comes from poor judgement.

View Dave's profile


11435 posts in 4080 days

#3 posted 03-12-2012 01:38 AM

Very nice and very impressive.

-- Superdav "No matter where you go - there you are."

View yrob's profile


340 posts in 4892 days

#4 posted 03-12-2012 01:52 AM

Very good job. I did one too but I had an advantage. I did it in the shop with Roy so his guidance helped me to not have it break the first time.

-- Yves

View pastorglen's profile


267 posts in 3930 days

#5 posted 03-12-2012 01:37 PM

Thanks for posting, everyone.

yrob – GOOD FOR YOU!! That’s a nice one, too. And I went into the first one knowing it was a practice. So it was a good learning opportunity. The second one was with the good stuff. And because the head is hardwood, too, it should last a while.

As much as I enjoyed making it on my own, in my shop, with Roy’s instructions nearby, I would have much rather joined your class in North Carolina. :-)

-- Glen, Pennsylvania, Colossians 3:23 "Whatever you do, work heartily, as for the Lord and not for men."

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics