LumberJocks

Shop Mallet

  • Advertise with us
Project by Fotodog posted 05-17-2020 02:39 AM 509 views 1 time favorited 2 comments Add to Favorites Watch

I’ve been wanting a nice mallet to replace my old store bought one, so I finally built it. It’s made from walnut and maple, my favorite wood combination. The head is made from 3 layers, with the middle maple layer made from 2 pieces cut at a 2 degree angle to form a tapered mortise. Both maple pieces have a 1 1/4” hole to accommodate steel BB’s for added weight.

The maple handle has a wedged tenon, which combines with the tapered mortise for a very strong joint. The contours of the handle were shaped with a belt sander on my homemade jig which holds the sander perpendicular to a small shelf, and also a round-over bit in the router table. Followed of course with lots of sanding.

Since you are fellow woodworkers, I have to disclose 2 mistakes, and my remedies to fix them. The first is the middle maple layer in the head, which is slightly wider on the bottom than the top. Since I don’t own a band saw in my small garage shop, I had to resaw a small piece on my table saw, and it apparently tilted slightly when ripping and I didn’t notice it in time. I considered scrapping the head and starting over once I noticed the mistake after the head was glued up, but after some thought I decided to see if I could still make it work. Which I did by offsetting the tenon on the handle in order to center it.

The second mistake happened when I was rounding over the handle with the router. A large chunk chipped out on the end. Instead of tossing it and starting over, I decided to cut off the handle a bit and add a walnut accent on the end. Since it’s an end grain joint, I strengthened it with a dowel.

Now I have a proper mallet, with a couple of reminders that all is not lost when mistakes are made.

-- Tim





2 comments so far

View Dave Polaschek's profile

Dave Polaschek

5432 posts in 1360 days


#1 posted 05-17-2020 12:26 PM

Looks like it’ll do the job. Well done!

-- Dave - Santa Fe

View jeffswildwood's profile

jeffswildwood

4452 posts in 2755 days


#2 posted 05-17-2020 12:34 PM

Well done mallet. I would have never seen the mistakes and still can’t find them. Mallets may start out pretty but don’t stay that way long. I wouldn’t worry about small errors.

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

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

HomeRefurbers.com