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Hand Tool Journey #21: New Mallet No. 3.. Advise Needed..

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Blog entry by Airframer posted 359 days ago 1257 reads 0 times favorited 14 comments Add to Favorites Watch
« Part 20: New Mallet No. 2 Part 21 of Hand Tool Journey series Part 22: Carvers Vise #1 »

I had a bunch of errands to run today which have kept me out of the shop. I just now had a chance to get out there to maybe get some shaping done on the handle when I noticed an issue with the mallet head.

It looks like some hairline separation of the glue joints have appeared since yesterday (or maybe earlier but I haven’t noticed them till just now). I am trying to figure out how to rectify this if it even needs rectifying.

Here are some pics of what I am talking about…

Top:

Bottom:

Now, since this portion will see a lot of impact force I imagine these need fixing if I expect this thing to last longer than a week I am just not sure how to proceed.

A couple options I am considering are bow tie’s on the top and bottom or placing some brass dowels into the 8 corners of the joints.. each of these options would be glued in place with 2 part epoxy instead of wood glue for added strength.

What would you do here (besides start over..)

-- Eric - http://theidiotgaloot.com



14 comments so far

View chrisstef's profile (online now)

chrisstef

10406 posts in 1605 days


#1 posted 359 days ago

Id just drill some holes and jam some dowels in it. Or leave it as is. There’s probably enough glue in there to hold things together.

-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty

View theoldfart's profile

theoldfart

3893 posts in 1050 days


#2 posted 359 days ago

I’m w/stef. dowels and epoxy. Butterflys won’t hold as well given the impact it will have to bare, bear aw hell whatever!!

-- "Aged flatus, I heard that some one has already blown out your mortise." THE Surgeon ……………………………………. Kevin

View PurpLev's profile

PurpLev

8476 posts in 2248 days


#3 posted 359 days ago

if the estetics don’t bother you (it would some people – not me), then I’d say just use it, theres quite a bit of glue surface between those block, and I doubt anything will come apart. This is mostly on the edges due to the fact that this is where the wood dries fastest, it may even balance itself out at some point once you finish the piece and left it aclimate

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Airframer's profile (online now)

Airframer

2282 posts in 552 days


#4 posted 359 days ago

Do you guys think it makes a difference if the dowels are wood or brass? I was thinking 8, 1/4” brass dowels sunk in here would add a bit more heft to it… or is that over kill lol..

-- Eric - http://theidiotgaloot.com

View theoldfart's profile

theoldfart

3893 posts in 1050 days


#5 posted 359 days ago

Only issue I foresee would be wood expansion/shrinkage, with wooden dowels everything should move together. I think the metal may loosen over time.
Disclaimer: the above is conjecture only, not based on experience.

-- "Aged flatus, I heard that some one has already blown out your mortise." THE Surgeon ……………………………………. Kevin

View FirehouseWoodworking's profile

FirehouseWoodworking

622 posts in 1872 days


#6 posted 359 days ago

Eric,

Like the previous comments, I would just leave it and drive on. But your last message gives me the impression that you want to fix it.

If you are bent on fixing it, why not just cut through the glue line with a bandsaw? Then joint the two faces and re-glue. You may need to take a little off the opposite face to make the mallet even on both sides of the handle, but the jointer can take care of that for you.

Cheers!

-- Dave; Lansing, Kansas

View Airframer's profile (online now)

Airframer

2282 posts in 552 days


#7 posted 359 days ago

I don’t necessarily want to “Fix” it so much as keep it from getting worse and falling apart. If you guys feel that it is fine I’m good with leaving it be really.

-- Eric - http://theidiotgaloot.com

View PurpLev's profile

PurpLev

8476 posts in 2248 days


#8 posted 359 days ago

overkill? in woodworking? what is that?

brass or wood dowels will not make a difference for wood movement as the grain is perpendicular either way. extra weight will only be a blessing in a – mallet. but It won’t add any additional strength to the glue line of the faces…

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View Don W's profile

Don W

14637 posts in 1167 days


#9 posted 359 days ago

my vote would be use it.

-- Master hand plane hoarder. - http://timetestedtools.com

View theoldfart's profile

theoldfart

3893 posts in 1050 days


#10 posted 359 days ago

Sounds like the group mind would bang away!

-- "Aged flatus, I heard that some one has already blown out your mortise." THE Surgeon ……………………………………. Kevin

View Mauricio's profile

Mauricio

6747 posts in 1751 days


#11 posted 358 days ago

I’d think wood dowel would keep it together better than brass.

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Airframer's profile (online now)

Airframer

2282 posts in 552 days


#12 posted 358 days ago

What I ended up doing was wicking some CA glue into the cracks and clamping the tar out of it over night. They are nice and sealed up now so I am leaving it as is.

-- Eric - http://theidiotgaloot.com

View chrisstef's profile (online now)

chrisstef

10406 posts in 1605 days


#13 posted 358 days ago

Smash something with it all ready will ya ;)

-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty

View Airframer's profile (online now)

Airframer

2282 posts in 552 days


#14 posted 358 days ago

Handle is in work still. I haven’t had much shop time in the last couple of days due to my work schedule but should be smashing stuff with it by this weekend.

-- Eric - http://theidiotgaloot.com

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