Sledge Hammer strikes back

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Project by fernandoindia posted 03-19-2012 04:47 AM 4478 views 1 time favorited 17 comments Add to Favorites Watch

Since everybody seemed to enjoy the making of their own tools, with their own hands. and the using of such tools, I decided to make a try.

I made a sliding bevel square with two blocks of Palo Santo ( lignum vitae), and a 400 mm (16”) long and 2 mm (5/64”) thick piece of bronze.

The square handle measures 25mm by 25mm and 130mm long. (I made that measures to be easy to translate to imperial, which would be 1” by 1” by 5.125”. The blade itself is 190mm( 7.5”)

Making the handle was straight forward. Apply CA glue and drilled 4 pilot holes through the bronze ends and the wood. I insert two 2mm bronze rods in the end, and 4 bronze screws in the top ends. (Were the bevel slides)

The most time consuming task was the drilling of the bronze to make the guide

Well not exactly the drilling, but the filing. And I´ll tell you it was quite difficult to me to keep it perfectly straight. (Needless to say, I failed in that one too)

FInally I screwed a 0,25” bronze screw and a wing nut to lock the bevel.

Very happy with the outcoming. But with such piece of bronze plus the Lignun vitae wood, the bevel weights only 300 grams (10.6 oz). Almost a Mallet.

I started trying as a mallet, but end to the conclusion that both the bevel square and myself would be much better off if I decided to make a mallet for my own.

Continuing the Mads spree on hand tools.

Since I had some other pieces of LV and other hardwoods lying around (VIraró and guatambu) (Not so nice as Mads ones), I start some ripping planning and sanding. Made two glue ups of 12mm (0.5”) guatambu (Yellowish); 6mm (0.25”) viraro (reddish); 3 mm (3/8”) guatambu. A third glue up was a 13mm ( more than 0,5”) sorrounde by two 2mm (5/64”) viraro

I did also turned the handle consisting of a piece of LV and two of viraró. The LV had some holes from screws (Was some old flooring scrap) Before assembling and gluing it I didn´t bother since I thought the sides of LV were to be covered by the other wood. Fool of me, didn´t think what would happen after turning it !!. (Still happy since this handle will increase my pricing due to the environmental friendly approach, :). This environmental alibi is great for fool woodworkers, isn´t it?

After cleaning, sanding all the blocks, I cut in half the third block, and glued to the handle and one of the other.

I the make a 30mm hole with a Forster bit, and fill the holes with lead.

Following the final glue up, and cutting the angle, I finished with 5 coats of Linseed oil within 3 days.

The head measures 12.5 cm (5”) 8 cm tall (3 3/16”), and 6 cm (2 3/8”) wide. Total lenght is 34 cm (13 3/8”)

Total weight is 1,150 grams (2.5 pounds or 40 oz)

-- Back home. Fernando

17 comments so far

View patron's profile


13722 posts in 4836 days

#1 posted 03-19-2012 04:54 AM

great work fernando

not just practical
but good looking too

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View lanwater's profile


3115 posts in 4429 days

#2 posted 03-19-2012 05:19 AM

Catching the tool making fever?

You did great. The sliding bevel came out nice. You just have to make a tool to ease the filling pain…

The hammer looks suspiciously like thor’s hammer; only I don’t think he had lead on the inside and yours looks much better.

Seriously, At over 1kg you are going to buil some serious muscles.

Great job my friend

-- Abbas, Castro Valley, CA

View Roger's profile


21055 posts in 4299 days

#3 posted 03-19-2012 06:06 AM

noooooo don’t hit that beautiful motorcycle fuel tank with that nice mallot…. lol ju kiddin. hand made tools are the best

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View Brit's profile


8520 posts in 4338 days

#4 posted 03-19-2012 09:17 AM

Lovely tools my friend. They will bring a smile to your face each time you use them. Well done.

-- Andy - Old Chinese proverb says: "If you think something can't be done, don't interrupt man who is doing it."

View JL7's profile


8793 posts in 4460 days

#5 posted 03-19-2012 11:53 AM

Fernando – nice job on the tools… wood, haven’t heard of a couple of those….and re-using the flooring, I love it…..that mallet looks pretty serious with the lead in it….wow!

AND – you included a photo of the BSA!! Very nice…what a wonderful classic.

Everything here is built to last…

-- Jeff .... Minnesota, USA

View RandyM68's profile


693 posts in 3813 days

#6 posted 03-19-2012 12:44 PM

I like the mallet. I built a bigger one but it is too light. I never even thought of putting lead in it. I did it with nunchucks and a billy club when i was a kid. Thanks for reminding me.

-- I can explain it to you, but I can't understand it for you. I'm sorry,thanks.

View lew's profile


13547 posts in 5251 days

#7 posted 03-19-2012 02:20 PM

These both look fantastic to me, Fernando!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View canadianchips's profile


2632 posts in 4492 days

#8 posted 03-19-2012 04:20 PM

I like the mallet, I REALLY like the finishing table it is sitting on. NICE.

-- "My mission in life - make everyone smile !"

View fernandoindia's profile


1081 posts in 4439 days

#9 posted 03-19-2012 04:24 PM

Thank you all for the kind comments

Ian, yes it is a way too heavy. Probably half weigh could be enough. WIth this weight, I just drop it.

Brit, thanks. I´ll smile each time I use it wondering what David meant about being good looking.

Thank you Jeff. As you see I´m also thinking of a striped shop :)

Thank you Lew. The next one will include a Celtic knot somewhere

-- Back home. Fernando

View fernandoindia's profile


1081 posts in 4439 days

#10 posted 03-19-2012 06:21 PM

CHips, glad you like it. I´m still improving my grating techniques. Looking closer to the table shows a lot of OOOOps.

I am finishing some shelves which I cut them with a new Freud thin kerf, and with a more dense wood.

-- Back home. Fernando

View stefang's profile


17040 posts in 4830 days

#11 posted 03-19-2012 07:10 PM

Excellent work on both projects Fernando. That mallet will be perfect for chopping mortises. The mallet and the sliding bevel are beautiful.

-- Mike, an American living in Norway.

View Martyroc's profile


2712 posts in 3801 days

#12 posted 03-19-2012 09:50 PM

Very cool, it’s a true craftsman that uses tools he has fabricated himself.

-- Martin ....always count the number of fingers you have before, and after using the saw.

View mm8ball's profile


7 posts in 3813 days

#13 posted 03-20-2012 04:00 AM

Great work on the mallet, but I want to know what brand and year is that motorcycle.

-- Thinking you know something is the most perfect barrier to learning.

View fernandoindia's profile


1081 posts in 4439 days

#14 posted 03-20-2012 02:23 PM

Stefang, Martin, mm8, thank you for your comments.

MM8, it is a BSA, A7 1947. My first motorcycle in 1969. Rebuilt in 2005. The photo links to photos of rebuilding

-- Back home. Fernando

View itsmic's profile


1419 posts in 4614 days

#15 posted 03-24-2012 12:04 AM

Hi Fernando

WOW, is that a sweet ride or what, looks like Your work on bikes is parallel to Your fine woodworking talents. It’s Great to have You here telling and showing all of us what You have been doing. Your tools look Great, I can really relate to “having to do things the hard way” You will always be in good shape anyway, and the reward for the hard work and ingenuity is a Great satisfaction. Your detailed discriptions always interst me and I always learn something, thanks Fernado, and thanks for sharing

-- It's Mic Keep working and sharing

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