Spiral End Mallet

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Blog series by Kent Shepherd updated 03-16-2010 06:57 PM 6 parts 15472 reads 62 comments total

Part 1: The Lay-Out

08-14-2009 10:47 PM by Kent Shepherd | 12 comments »

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 en...

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Part 2: The Router Jig

08-17-2009 06:24 AM by Kent Shepherd | 7 comments »

OK, here’s the second of our series. We left off showing the bottom side of the jig. I have drilled a hole for the T-bolt in the jig. distance is not critical, but the hole will be about a third from the end in the clamping piece itself. On the underside of the jig, countersink for the head of the t-bolt. I did this with a forstner bit on my drill press, drilling about 3 holes side to side, then cleaning it up with a chisel. This doesn’t need to be precise, just make room for the ...

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Part 3: Cutting & Glue-up

08-17-2009 07:24 PM by Kent Shepherd | 7 comments »

After rounding the first side of the pieces, you will need to set up for the other side. Remember, we have 2 jigs, one for each side of the pieces. I told you from the start you would be dealing with only one radius, which you determimed at the beginning of the project. I kept my compass set, and will need it at this time.The position of the work piece is critical now. Take the compass and draw an arc on the jig. Place the pivot point right on the edge of the routed slot in the jig. Note̵...

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Part 4: Banding the Medallion

08-19-2009 05:55 AM by Kent Shepherd | 12 comments »

As we progress to step 4, I do hope you’re finding this worthwhile. Even if you never make a “Spiral End Mallet”, maybe the principals here might be useful in other projects. If I see you adapting some of these ideas, then I will feel like I actually accomplished something with the blog. I’ve not done a blog like this before, so your input is important to me. Now—-lets see how to band the medallion. This is much simpler to explain than the last part. First you...

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Part 5: The Mallet Itself--Final Chapter!!!!!!!!!!!!

08-24-2009 10:17 PM by Kent Shepherd | 16 comments »

So, by now you’re asking—Mallet, what mallet? Really, there is a mallet. Amazing, I could spend 4 sessions showing you how to make a little 2” disk. The good news is, that was the Hard Part. I’m assuming if you’re going to actually make this project, you already have a lathe and know how to use it. If you depend on me to teach you to turn, we’re both in trouble. My experience is rather limited in this area.. That said, you’ll see how basic this part r...

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Part 6: Fine Woodworking Contest

03-16-2010 06:57 PM by Kent Shepherd | 8 comments »

I noticed Andy’s Eye Candy Box made the finals in Fine Woodworking’s Scraptacular contest.Congratulations Andy—-However, so did my Spiral End mallet. So, in the spirit of a little friendly competition———Vote for ME! if you are a subscriber to Fine Woodworking’s web-site.

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