LumberJocks Woodworking Forum banner

Project Information

Initially, I wasn't going to participate in the Mallet Swap. However, I came across a picture of the H.O. Studley infill mallet and decided I wanted to try and replicate it.

The first question that came to mind is who is Henry O. Studley and why is he so important? It turns out that he was an organ and piano maker, carpenter, and Mason who worked for the Smith Organ Co. and later for the Poole Piano Company of Quincy, Massachusetts. Studley is best known for creating the so-called Studley Tool Chest, a wall hanging tool chest that cunningly holds 218 tools in a space that takes up about 40 by 20 inches of wall space when closed. To me, the more important aspect is the amazing quality and beauty of his tools and work bench.



Studley gave the tool chest to a friend. That man's grandson, Peter Hardwick, loaned the chest to the Smithsonian in the late 1980s as part of an exhibit at the Smithsonian Institution's National Museum of American History, until it was purchased by a private collector for an undisclosed amount of money. The current owner continues to lend the chest to the Smithsonian and other venues. It has been featured on an episode of The New Yankee Workshop and is the subject of a May 1993 article in Taunton's Fine Woodworking and a popular wall poster.

The mallet caught my eye:



The brass details are exquisite:







I had no idea how to do the brass work, but some conversations with HokieKen and a lot of looking for square stock on line provided the answer. I was able to find some 1/8" thick, 1-1/2" square brass tubing. Kenny cut the angled ends for the head, bored out the handle opening, and as a bonus, put the beveled finials on as well. The finials make the mallet as far as I'm concerned. I owe a HUGE thanks to him for the work he put into this mallet.

The brass work was the hard part - THANK YOU KENNY!!!

The wood section of the mallet is a piece of Brazilian Ebony with a 3/4" mortise and beveled edges.

From there, I inset some brass triangles into the handle and pinned them with silver nickel pins







Some shaping on the handle and mallet was ready for finishing. The brass was polished and the handle was finished with Watco and wax.

Specifics:

The handle is Bocote with a brass inlay, pinned with silver nickel pins.
The wooden portion of the mallet head is Brazilian Ebony.

As a bonus item, I also sent along Virtuoso: The Tool Cabinet and Workbench of Henry O. Studley

Kenny sent me an extra brass head piece so I can make one for myself. I will need to learn how to work with brass better before I try to finish it.

Gallery

Comments

· Premium Member
Joined
·
7,336 Posts
Awesome bit of history (I bet they have the reproduction of Studley's cabinet at Handworks again this year) and great reproduction Earl and Kenny. Corntastic work, boys!
 

· Registered
Joined
·
343 Posts
I was unaware, thanks for sharing.
 

· Registered
Joined
·
980 Posts
As always l'm humbled and awed by your work. Superb!
 

· Registered
Joined
·
4,961 Posts
Awesome work Earl and Kenny! It looks stunning! Great inspiration for a beautiful mallet.
 

· Registered
Joined
·
2,261 Posts
Excellent work!!
 

· Banned
Joined
·
18,919 Posts
exquisite work my friend,that is the work of a master.studley i know him well,i have a poster of his tool chest in my shop.anyone that that takes that much pride in their tool chest is a master in my opinion.id would love to have seen his work.earl do you have the hard bound book on the tool chest,it's very detailed going into depth the tools and the chest and workbench.once again beautiful work.
 

· Registered
Joined
·
4,322 Posts
pottz - I ordered the book as a bonus item for Keebler - my swap recipient. I glanced through the book and it is on my Christmas list.
 

· Registered
Joined
·
5,099 Posts
The book is phenomenal. I definitely want one. Now that we got some better pics of this mallet it's my favorite of the swap. I heard ahead of time you were making this and was super excited to see it. You didn't disappoint!! Beautiful!

Good job friend!
 

· Registered
Joined
·
795 Posts
Morning Earl,
I just woke up, 8 am here in Hong Kong, and your mallet swap project post was the one I was really waiting to see. As i pressed the ZOOM PICS button I found myself subconsciously whispering words under my breath. I caught myself towards the end and listened to what I was saying which was "THAT IS ABSOLUTELY HEAVENLY, ABSOLUTELY HEAVENLY" That is was what the subconscious brain was saying , now I type conscientiously and I realize those words where an understatement. Honestly speaking those ,especially the brass one is a true work of art, and further to that an extreme act of kindness to give such a beautiful piece away to another Lumberjock.
Well done Earl, Superb. Also a shout to Kenny for helping with the brass, hes number one on the metal work around here.
Great project.
Kind regards
Anthony

EDIT oh and topped off with the History you shared with us all.
 

· Registered
Joined
·
21,780 Posts
It's a winner for sure Earl! I love how you did the inlay in the handle. I can handle machining but that inlay stuff is too artsy for my brute force. Glad I could help and thanks for the shout out and the extra material to make my own head :)

If you send me your head back, I'll add the finials to it.. i really didn't realize how much it adds until I saw the finished piece.

As far as I'm concerned, you and Dave are neck and neck for the "winner" of this swap. I'll reserve final judgement on who is ultimately the winner until y'all's bribes are in.
 

· Banned
Joined
·
18,919 Posts
hey guys seeing all this amazing work you do really inspires me everytime i come on line here,and im not just blowin smoke im very sincere when i talk about the talent we have here on lj's,except kenny who has super powers and doesn't count among mortals….....just kidding,he inspires me everyday.congrats to al that make this a place we can all come and learn and grow our passion,thank you all.
 

· Registered
Joined
·
3,100 Posts
So nice. I have got to start using brass. Buddy, I can tell you did a lot of work on this one!
 

· Registered
Joined
·
1,434 Posts
Wow. Incredible workmanship on that. Well done.
 

· Registered
Joined
·
6,567 Posts
Nice work Earl. That has a look of authority about it.
 

· Registered
Joined
·
1,361 Posts
That thing is a work of art.
It's no clock-mallet-combo, but it comes close!
Is the design intended to allow replacing the head periodically?
 

· Registered
Joined
·
6,567 Posts
I'm getting the idea there are as many metal workers here as woodworkers. A lot of companies would be proud to have as many solid products in their line as you guys are putting out.

Congrats.
 

· Banned
Joined
·
5,339 Posts
what to say that has not been said already you are a master GREAT JOB :<)) GRATZ TOP 3
 

· Registered
Joined
·
2,183 Posts
Earl you made a wonderful tribute of the Studly Mallet. Kenny did a nice job too!
 

· Registered
Joined
·
4,322 Posts
John - it is intended to be able to replace the head. Studley used a nail or screw instead of tapered shims.
 

· Registered
Joined
·
37 Posts
Both of you deserve all the praise that has been sent your way. I'm in awe, impressed and inspired. So many questions. Where did you get measurements from? What was the size of the wood in the head of the mallet. I was impressed with Mr. Studley's tools and chest before FWW ever ran the photo spread, I need to get the book.

Thanks for any additional info that either of you can provide.

Wally
 
Top