Project by PurpLev | posted 08-15-2010 11:05 PM | 5805 views | 18 times favorited | 27 comments | ![]() |
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Pallet to Mallet,
a Mallet from a Pallet.
I needed one for a very long time as I always seemed to be using the closest available heavy block of wood for chisel work. I ended making this one from a single Oak pallet slat that had some nice figure to it.
head is 3”x5”x~2.5” – laminated 4 layers
handle is 1 1/4x~1 1/4”x as long as I could have it (for balance). It’s ~16” long (through the 3” head)-laminated 2 layers
The handle is not glued to the head, but is wedged in. the inner parts of the head are cut at 2° on each side, and a wedge with edges at 4° once pounded in (with glue) presses the handle tight into the head, while also keeps it from moving with the now wedged/slopped handle top – its basically locked in.
The head faces are both cut at 1° slope to follow the direction of the blow better.
finished with 2 coats of BLO.
-- ㊍ When in doubt - There is no doubt - Go the safer route.
27 comments so far
jack1
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#1 posted 08-15-2010 11:18 PM
Looks like a good mallet. It does have a good figure.
-- jack -- ...measure once, curse twice!
Lenny
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#2 posted 08-15-2010 11:29 PM
That’s a great save Sharon. Pallet to mallet indeed. Instead of being in a landfill, this oak will be helping you make fine projects.
-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI
littlecope
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3157 posts in 4999 days
#3 posted 08-15-2010 11:47 PM
Good Looking Mallet, Sharon… Being Oak, that must have some nice heft to it…
-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.
Gary Fixler
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#4 posted 08-16-2010 12:20 AM
Very nice! I might like to follow along with my own mallet one of these days. I have a lot of pallet wood here.
-- Gary, Los Angeles, video game animator
PurpLev
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#5 posted 08-16-2010 12:24 AM
Thanks guys,
Mike – as for the heftiness. I was surprised by how light it felt once I got all the parts cut out for it. not that it’s light – but I guess I was expecting it to be heavier. it does good though – it has a very balanced feel to it both in total weight, and in head-to-handle balance.
-- ㊍ When in doubt - There is no doubt - Go the safer route.
ellen35
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#6 posted 08-16-2010 12:41 AM
Very cool, Sharon!
I love the price!!
-- "Don't let the perfect be the enemy of the good." Voltaire
David
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#7 posted 08-16-2010 12:41 AM
nice looking mallet. Even if the heft is not what you were expecting, the long handle will give you the leverage you need.
-- “Don’t tell me what can’t be done, tell me what you want done then shut up and get out of my way and let me do it!”
Karson
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#8 posted 08-16-2010 01:20 AM
Very nice Sharon. A great use of recycled materials.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected] †
PurpLev
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#9 posted 08-16-2010 01:35 AM
Dont get me wrong folks – it’s hefty enough :) I guess my point was more that I thought it would just be heavier – which I am glad it’s not since that would put unnecessary strain on me.
As for recycling materials – I originally had mighty plans for these pallets for some outdoor projects, and milled/laminated boards together to get thicker boards that I can actually work with. it took 9 slats and 1/4qt of glue to make 6 1.5”x1.5”x40” boards and 1/2 a day of labor – all in all, I am still not sure the electricity use, planer blades (adding total usage) and the time would qualify this as being green. But thats what I have to work with, and so far so good.
This mallet on the other hand only used 1 slat, and minimal labor – so I would definitely consider this one green!
-- ㊍ When in doubt - There is no doubt - Go the safer route.
SPalm
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#10 posted 08-16-2010 01:54 AM
Looks like a good wacker.
How did you attach the head? You say it is laminated, so I can guess…
Steve
-- -- I'm no rocket surgeon
Lee A. Jesberger
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#11 posted 08-16-2010 02:19 AM
Hey Sharon,
Nice mallet pallet!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
moonls
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#12 posted 08-16-2010 02:29 AM
Good work Sharon! Many of my projects are made from recycled wood. I hate too see good wood go to waste!
-- Lorna, Cape Cod
PurpLev
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#13 posted 08-16-2010 03:44 AM
Steve – I uploaded 2 more pictures to show you the attachment of the head – it has nothing to do with the lamination – although since all the parts come from a single board, it was easier to get a perfect fit in thickness. that aside – the construction is just a standard wedge with edges at 4° to one another. the center head-blocks inside are cut at 2° on each side, so that the wedge will create a perfect fit between all parts inside and eliminate gaps once pounded in.
since the head and handle grain go in perpendicular direction – I’m not sure it would be wise to otherwise glue the head to the handle – which again was another reason I chose the wedge method.
The mallet head front and back (end grain parts) are cut at 1° slope.
Lee – when all else fails – I can always use the mallet to ship merchandise :)
Thanks Lorna – I know exactly what you mean about seeing good wood go to waste. and hardwood pallets usually have a high percentage of good usable material. only thing is – it takes some work to get it to a usable state :)
-- ㊍ When in doubt - There is no doubt - Go the safer route.
swirt
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#14 posted 08-16-2010 03:50 AM
Nice mallet and thanks for including the x-ray view form Sketchup. ;)
-- Galootish log blog, http://www.timberframe-tools.com
PurpLev
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8654 posts in 5145 days
#15 posted 08-16-2010 03:58 AM
glad it’s helpful swirt
FYI: I just drew the SketchUp model now to illustrate how I built the mallet earlier (using my BoardMaker plugin by the way ;) ).
-- ㊍ When in doubt - There is no doubt - Go the safer route.
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