Here is the the build process of the little tapper that I use.
I start by sourcing most pieces I need from the scrap bin and cutting them to size .
Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Note the little handy bevel gauge that my buddy Paul http://lumberjocks.com/shipwright made for me and it is just a great little tool .
If you look back in my projects you will find the post of my sled http://lumberjocks.com/projects/61820 which has a double bottom that allows me to tilt the blade and maintain a zero clearence to the blade by sliding the top layer against the blade at any tilt angle .
Now you can see all the pieces and the order of how they fit together .
Here is the glue up and almost all pieces that make up the mallet are glued together in one clamping .
The open section has spacer blocks inserted to allow that laminated section to be shaped and easily clamped .
Here is a little paper pattern I use to mark out the shape of the head which is followed by cutting with the bandsaw and sanding on the disc sander,
The squeeze out glue on the handle is scraped off and followed by planing.
Here are the handle scales glued on and the wedges in stalled .
Now on to shaping the handle with a spokeshave clamped in my new twin screw vise http://lumberjocks.com/projects/105719
,I thoroughly enjoy all the clamping option that this vise gives me .
The open section being filed, sanded and shaped with whatever works and sandpaper strip does a nice and quick job of this after removing most of the material with the file .
The buttend cap gets glued on and here I apply glue to the handle first and let it dry and then with more glue clamp on the cap ,doing it this way gives a pretty strong glue joint on endgrain .
A special little insert I choose for this one and the leather faces getting glued on .
Here is the first mallet from the batch of three all cleaned up with a coat of bees wax and ready to be given .
I made three and all are just a little different with different inserts and slight different handle sizes to allow me to match them better to the recipient .
I just love making these and enjoy the smiling faces when I present .
Thanks for following along and if there are questions please let me know .