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Greetings all,

Here is a set of mallets that I recently made for LJ clieb91 for the Shop Made SURPRISE Tool Swap - Fall/Winter 2016.

All the handles are made out of some walnut that was a left over from my countertops, but the heads are all made of different materials.

The small one - weighing in at 24oz is a slug of 1 5/8" brass
The medium one - weighs in at the waif weight of 9oz of Osage Orange
The big clobberer - weighs in at a hefty 25oz - of veg tan leather discs sandwitched between two discs of Osage.

All mallets have a lag bolt with the head cut off attaching handles to the heads. The bolts in the handles go at least halfway down to help with balance and strength.

The bolt in the brass only goes up about an inch, in the wood about 2", and it goes all the way through the leather mallet.

There were a few questions about the leather mallet over on the swap forum that I'll address here.

The leather is the thickest veg tan I could find at the local leather shop. I used a 3" hole saw on my drill press to drill out the discs. I will say my crappy hole saw and 1/3hp drill press made this a challenging job and some had to be finished off with a utility knife.



Here's a shot of the discs loosely stacked.



Here's a shot after gluing up with Weldwood



After the glue cured for a couple days I assembled all the rough pieces and epoxied them together. Note: the bolt is standing proud of the head.



I mounted the bolt into a drill chuck in my lathe. Everything rounded



Final shape



I had never tried to turn leather before, but to my surprise it turned fairly easily. I used my carbide tools. High speed. But the stock removal was slow. You can't lean into it like you can with wood to hog off a bunch quickly - it's slow going, but works fine.

Once that was all done I cut the bolt off and smoothed the top out.

I hope that helps with any construction questions.

TerryR recieved my name for the swap and he had a very similar idea for the swap that I did. I was lucky enough to get three mallets from him as well. A bass, wood, and plane adjuster. The fit and finish of these tools are paramount. Thanks Terry!





It was a fun swap. A big thanks to Dave for putting this shindig on.

Any questions and/or comments welcome.

Thanks for reading.

Gallery

Comments

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1,819 Posts
Awesome work Todd. Your leather mallet is very cool, I want to try that now.

Congrats with the nice set of swingers clieb! Not changing it.
 

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5,965 Posts
Nicely done, Todd. The leather mallet looks like good alternative to a polyurethane carving mallet. I'm also surprised the Osage didn't weigh more.
 

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5,099 Posts
Great write up on the leather mallet. Thank you sir. Great looking set leaving and coming to your shop.
 

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2,212 Posts
Mallets are raining from the sky. Well done, those look really nice. Great handle duplication skills.
 

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3,100 Posts
Great set Todd. I had really wondered how you did the leather mallet. All are beautiful and I'm sure will last for years.
 

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18,919 Posts
great job anyone would be proud to get those.
 

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7,180 Posts
Thanks, Todd.
Love your stuff, Thanks for the tutorial on stacking leather. Gotta try that one.
 

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21,780 Posts
Great stuff Todd. I like that handle style and the leather looks like a versatile tool. Definitely be copying that one!
 

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584 Posts
Beautiful work

Informative

Inspirational

GREAT!
 

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5,776 Posts
Very nice sir. I imagine all those will be very useful tools.
 

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8,658 Posts
Todd your's and Terry's mallets inspired me to turn a couple far less fancy users for myself despite the fact I don't do any carving nor do I have any carving chisels. The shape is just so appealing and for the most part uncomplicated, I ended up just grabbing a couple branch chunks of unknown wood and went to town. The second turned out much better than the first. The craftsmanship you have put into these is amazing and the leather is very unique even though it looks like it was fairly labor intensive, I'm sure it'll be great to use.
 

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8,547 Posts
Thanks gang!
 

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17,161 Posts
Love em todd. Those are my 3 favorite mallet shapes and the most used in my shop. A big fatty for really beatin on stuff. A nice light weight carving mallet and a lil baby tapper that i can still put some oomph behind if needed.

I gotta get in on a swap again. I havent done one since mallets back in the day.
 

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2,094 Posts
Beautiful stuff, Todd.
 

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Todd very nice.
How did you do the little brass one? I've got a very cheap and small lathe, not sure if I have enough HP or torque (or whatever you'd need) to do it.
 

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Get on it, Stef.

Travis, yeah, just used the wood lathe. Carbide tools work just fine.
 

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Fantastic mallets Todd!
 
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