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Homemade Tools #2: Wooden Dead Blow Mallets

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Blog entry by Lee A. Jesberger posted 07-03-2008 01:45 PM 11490 reads 4 times favorited 35 comments Add to Favorites Watch
« Part 1: Block plane and Joiner Plane Part 2 of Homemade Tools series Part 3: Attaching the leather »

I saw an article in a woodworking magazine, maybe it was shop notes, on making wooden mallets that were filled with lead pallets.

I made up a few of these, some I gave away, others are still hanging around.

They’re easy to make, and useful around the shop. Not to mention they look great and are a good use for small scraps of exotic woods.

The ones below don’t have the leather contact cemented to the face of them. It’s this leather that keeps them from marring the surface of the wood your hitting.

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-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com



35 comments so far

View teenagewoodworker's profile

teenagewoodworker

2727 posts in 2424 days


#1 posted 07-03-2008 01:49 PM

cool. those are beautiful and functional. can’t get much better than that.

View Josh's profile

Josh

119 posts in 2594 days


#2 posted 07-03-2008 01:52 PM

I guess you do run out of tools to buy when you build your own. Those are very nice.

View Karson's profile

Karson

34876 posts in 3056 days


#3 posted 07-03-2008 02:09 PM

Lee a nice heft to them with the Lead shot. And they look great in person. Nice Job and thanls for the picnic.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View gizmodyne's profile

gizmodyne

1763 posts in 2746 days


#4 posted 07-03-2008 02:36 PM

Nice. I want to make a dead blow. I found the article or a plan at least

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Damian Penney's profile

Damian Penney

1140 posts in 2647 days


#5 posted 07-03-2008 03:04 PM

Very cool looking, I love shop made tools.

-- I am always doing that which I can not do, in order that I may learn how to do it. - Pablo Picasso

View PurpLev's profile

PurpLev

8476 posts in 2304 days


#6 posted 07-03-2008 03:34 PM

those are beautiful. definitely on my list of to-dos… just waiting to have enough scrap pieces for it … haha (I keep finding uses for all my scraps , and at the end of the job am left with nothing but 1×1x2 pieces… what the hell?!?)

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

View SPalm's profile (online now)

SPalm

4819 posts in 2538 days


#7 posted 07-03-2008 04:22 PM

Hey Lee, those look fine.

How is the maple one hollowed out? Is the shot able to flow inside from end to end, or are there two seperate chambers? About how much shot does it take?

Steve

-- -- I'm no rocket surgeon

View PaBull's profile

PaBull

928 posts in 2321 days


#8 posted 07-03-2008 04:29 PM

http://www.woodworkingonline.com/wp-content/uploads/2006/11/Joiners%20Mallet.pdf
This is a free link with very nice instructions. I might build me one of these, thanks Lee!

-- rhykenologist and plant grower

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#9 posted 07-03-2008 04:37 PM

Hi denis;

Thank you;

These are great fun to make! Very useful, and it sure beats throwing away scraps of exotics.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#10 posted 07-03-2008 04:38 PM

Hi Josh;

That’s no problem. Just buy newer models. lol

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#11 posted 07-03-2008 04:40 PM

Karson;

It was absolutely my pleasure!

Funny how we plan certain things to try, and then get side tracked to every thing but what we planned!

I think it’s more enjoyable just to go with the flow.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#12 posted 07-03-2008 04:44 PM

Hi John;

I’m not sure if that’s the same plan or not. But it sure looks good!

There are so many variations that can be made it’s crazy.

It’s rare that I spend a day in the shop without using mine. Even if it’s just to knock some sense into me, or jar my memory loose!

In fact mine is probably ten years old and about time to replace it. (maybe retire it to a wall somewhere)

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#13 posted 07-03-2008 04:53 PM

Hi Purplev;

I missed you joining up so WELCOME to LJ’s.

I like your signature line.

If all your scraps are that small. you’re doing something right.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#14 posted 07-03-2008 05:00 PM

Hi Steve;

They’re handy and fun to make for sure.

The center layer is actually two pieces, one on either end of the handle. One end of the piece is flat and becomes the face. The other end is cut on an angle, which locks the handle in when the wedges are driven into the end of the handle.

It has a hole about 1” in both pieces. These holes are filed most of the way with pellets from a pellet gun. (available in a sporting goods store).

If you fill them to much the extra whack from the shot moving will be lost and reduce the effectiveness.

I’m sure you’ll enjoy making these.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View Lee A. Jesberger's profile

Lee A. Jesberger

6648 posts in 2635 days


#15 posted 07-03-2008 05:01 PM

Hi Damian;

You can make a few to match your bench.

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

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