# Spiral End Mallet #1: The Lay-Out

 Blog entry by Kent Shepherd posted 08-14-2009 10:47 PM 1819 reads 16 times favorited 12 comments
 no previous part Part 1 of Spiral End Mallet series Part 2: The Router Jig »

Thanks for your interest in my new Spiral-End Mallet, based on the Lazy Larry Spiral Cheese Boards, by degoose. Obviously with the small size of the pieces, the band saw jig Larry uses wouldn’t work. This is how I adapted his GREAT idea for something a little different.

The first step is to make the medallion that is inlayed in the end of the mallet. (Yes it is inlayed—-do you think I’m totally nuts?) If you are looking for a fast, easy project, this may not be it, but the end result is well worth the effort. As you see from jigs I’ve posted, I usually don’t take the easy way out. —-But it sure is FUN.

HERE WE GO!

First, do the math—-or maybe a little Geometry. You need to establish the size you want the medallion, which obviously is related to the diameter of the end of your mallet. Mine is 2 7/8”. My medallion finished out at
2 1/8”, including the band around the outside. The radius you need for this size is 1”. Set your compass on that measurement.—-Note—You certainly may change that to fit your needs, especially if you do another application, like coasters for instance. The principal remains the same, you just change lay-out sizes and create router jigs to accomodate. Draw a circle on any scrap piece.

Now place a mark at any point around that circle and draw an arc from that point through the center of the circle you drew.

OK are you still with me. It’s really not that complicated is it. Now place your center point where you crossed the outside of the circle, and do it again untill you have this. Again, it’s the same radius—You never change your compass.

Now you can start actually building something. The Router jigs began with a base clamped to th router table top. I drilled holes to accept the pivot bolt on the cicle jigs that clamp the workpiece.—You’ll see! I drilled a series of holes on 1” increments to use for other diameter spirals later. I had some plastic tubing that is pressed in the holes. It operates smoother, and will last much longer. Find some that will accept your pivot bolts. I used 1/4” bolts. You want it snug. Drill the holes the OD of the tubing, and glue it in—-Super Glue is fine. Yeah I know, mine’s sloppy. I get in a hurry too sometimes. The slot is for the spiral bit. You will need it to adjust things later, especially if you do a larger diameter later. The bottom of this base has a runner mounted that fits the miter slot. If you don’t have one, use something to hang over the edge to keep everthing lined up. It’s important later.

Now, the clamping jigs. There are two, One for the inside and outside radius. They are 1/2” Baltic Birch Plywood. Dimensions are not important here. Drill a 1/4” hole for the pivot bolt. Take a bolt and cut off the theads, so that only the shoulder remains. The length is enough to protrude from the bottom about 3/8”. I countersunk the bolt head and epoxied into the jig from the top. Next place the bolt into the base. With the router bit below the table start your router, and raise up through the jig. The pivot hole must be exactly the distance from the bit as the radius you have already established. Remember the lay-out step. After plunging the bit, move the top jig in a circle on the pivot bolt. Only go about halfway around (You don’t want to cut a hole in your jig now—do you?)

That’s it for now. I’ve typed way past my limit. Stay tuned for Part 2, coming soon. I’ll show you how to make the clamps. Critical if you want to keep your fingers—-Remember how small these pieces are.

-- She thought I hung the moon--now she just thinks I did it wrong

## 12 comments so far

 PurpLev8476 posts in 2394 days #1 posted 08-14-2009 10:51 PM sweet. Thanks for the how-to.. gonna follow up on this one. -- ㊍ When in doubt - There is no doubt - Go the safer route. majeagle11418 posts in 2242 days #2 posted 08-14-2009 11:10 PM Great blog Kent, looking forward to the remaing parts….................. -- Gene, Majestic Eagle Woodworks, http://majesticeagleww.etsy.com/, http://www.flickr.com/photos/majesticeagle/ degoose7051 posts in 2101 days #3 posted 08-14-2009 11:59 PM What no BUBINGA?Kent you do write a mean blog, and the pics are great.Nice to see people looking outside the box.I think that the jig would look good with and inlay of PH lol -- Drink twice... and don't bother to cut... @ lazylarrywoodworks.com.au For lovers of all things timber... Grumpy19693 posts in 2597 days #4 posted 08-15-2009 01:37 AM Great Blog Kent. Thanks -- Grumpy - "Always look on the bright side of life"- Monty Python mmh3480 posts in 2468 days #5 posted 08-15-2009 01:48 AM Beautiful! I want one! -- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe Joe Lyddon7934 posts in 2798 days #6 posted 08-15-2009 06:06 AM Kent, thank you… I’m still tuned-in for the rest… :) -- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500" jockmike210635 posts in 2992 days #7 posted 08-15-2009 01:20 PM Very cool design, even though you stole it from Larry. -- (You just have to please the man in the Mirror) Mike from Michigan - patron13165 posts in 2087 days #8 posted 08-15-2009 01:31 PM your jig is great ,opens lots of doors . waiting for the rest ,maybe today ? -- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle Kent Shepherd2698 posts in 2032 days #9 posted 08-15-2009 04:21 PM Larry, Want Bubinga?——-See part 2. I guess Purple heart might work. David,——Soon -- She thought I hung the moon--now she just thinks I did it wrong cabinetmaster10874 posts in 2304 days #10 posted 08-16-2009 03:49 AM I’m watching Kent…...............Gotta see more. -- Jerry--A man can never have enough tools or clamps a1Jim112828 posts in 2323 days #11 posted 08-16-2009 07:42 AM cool kent -- http://artisticwoodstudio.com Custom furniture mafe9670 posts in 1835 days #12 posted 10-01-2010 05:49 PM The coolest mallet ever seen!A smile and a wonderful thought,Mads -- Mad F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

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