Reply by mramseyISU

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Posted on Quarantine projects

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594 posts in 2315 days

#1 posted 04-13-2020 01:50 PM

As I was cleaning up my shop from the chair project I dropped my old mallet and split the handle. So that got me started on the next project, a new fancy mallet. I had a little piece of purple heart in the scrap bin leftover from something but it wasn’t big enough for much but I figured I could laminate a mallet head out of it.

I decided to do this mostly with hand tools, at least the joinery so here are all the tools I used ready to go.

I laid out the joint where the handle would go.

Then I removed the waste starting with a knife wall and ramp carved with a chisel to guide the saw. Once I sawed the cheeks I removed the waste with a router plane. Just as a side note that router plane is hands down my favorite tool in the shop. I use it on almost every project I make. I never trust that my dadoes or rabbits are the right depth over the length of my cut so I always touch them up with it and it never fails I find a high spot or two.

Checking the fit it appears I had a little clean-up to do so both sides matched up. Once that was done I cut the dovetail on my handle but didn’t take any pictures of that. I made the cut with my carcase saw and cleaned it up with a block plane and chisel.

Got it in the clamps and the glue is drying. I’m going to cross pin it with some maple dowels to match the handle so I ordered that last night. FYI McMaster had dirt cheap dowel rod in several species. It was about 1/3 the cost of ordering it from Rockler or Woodcraft. The closest source I have for anything other than popular dowels is a 2 hour round trip so I’m money ahead ordering it from McMaster.

-- Trust me I'm an engineer.

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