A few months ago I made a simple mallet out of an oak cut off and a 1” dowel. It has done a good job but has always been a bit on the light side and has started splitting on the top from trying to use it to chop some mortises.
Well, last night it finally just gave up. One face is still usable but I think it’s time for it to retire..
I have been planning an upgrade ever since I finished the first one but never really had the motivation to put some other projects on hold long enough to do it. Well…. this was my motivation. It was time to make that upgrade.
Gathered up some hard maple, jatoba and grabbed some BB’s from WallyWorld and got to work.
The head measures 7” x 3 3/4” x 2 1/2” . That will reduce some after final shaping but I want to keep it a bit on the biggish side of things…. I mean what can’t be fixed with a bigger hammer?
In the center laminate on each end I drilled a 1 1/2” hole and filled them full of BB’s to give it more weight. I have yet to actually weigh it but it feels good and heafty and makes my old mallet feel like it’s made of styrofoam.
The handle is being made from more maple with some jatoba accents in the shoulder area and down in the grip to help round that part out a bit.
First was to cut the tenon to fit and then leave that part alone and focus on rough cutting it to shape.
Attempted a resaw on some jatoba with my craptastic Ryobi band saw… it doesn’t do that so well.
Used some double sided tape to secure the 2 halves onto some backer board and clamped that board to the bench so I could plane these flat (really need to finish THIS BENCH!)
Cut out the pieces and glued them up. BTW DonW’s pointer on using some salt to keep the pieces from sliding around during glue up is boss! Works like a charm!
The ovals will have a recess cut into them and some leather inserted for comfort and grip (that’s the plan anyway).
Now just waiting on the glue to dry so final shaping can commence and final assembly. Stay tuned!
-- Eric - http://theidiotgaloot.com