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Kiefers Little Tapper build

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Blog entry by kiefer posted 10-01-2014 02:38 PM 3499 reads 45 times favorited 24 comments Add to Favorites Watch

http://lumberjocks.com/projects/106249
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 .

Klaus

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos



24 comments so far

View  woodshaver (Tony)  's profile (online now)

woodshaver (Tony)

4031 posts in 2819 days


#1 posted 10-01-2014 03:10 PM

Excellent tutorial Klaus. All the pictures are nice to see and they make it easy to understand your methods. Thanks for sharing and taking the time to put this together. Well done as usual!

-- Tony C UAW, St Augustine FL, My high school shop teacher said "You can do it"... Now I can't stop!

View shipwright's profile

shipwright

7174 posts in 2264 days


#2 posted 10-01-2014 03:13 PM

These are so nice Klaus. Your innovations are just brilliant …...... and it’s nice to see the little bevel in use as well.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

View Jim Jakosh's profile

Jim Jakosh

17188 posts in 2572 days


#3 posted 10-01-2014 03:21 PM

Very nice, Klaus. Most people would not know what goes on behind the scene when making these type mallets. Very fine workmanship!!
Thanks for showing it to us!!!!!!!!!!!!!!!!!!!!!.............Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View stefang's profile

stefang

15512 posts in 2801 days


#4 posted 10-01-2014 03:33 PM

I love this design Klaus. Thanks much for showing us how to make them.

-- Mike, an American living in Norway.

View Woodbridge's profile

Woodbridge

3460 posts in 1884 days


#5 posted 10-01-2014 03:34 PM

A great little mallet. I really like the design. Thanks for sharing your build process with us.

-- Peter, Woodbridge, Ontario

View kiefer's profile

kiefer

4881 posts in 2133 days


#6 posted 10-01-2014 03:53 PM

Thanks and you are all very welcome and I hope it is of use and inspiration to some .
I love this little mallet and use it daily for all kinds of things .
Paul thanks for that little bevel gauge and it is sure one great little tool .
I made a little modification to it and find I can open it without tapping it against something ,I hope you don’t mind .

Klaus

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos

View shipwright's profile

shipwright

7174 posts in 2264 days


#7 posted 10-01-2014 04:01 PM

A little personalization never hurts.
It shows me you actually use it and that makes me happy.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

View HillbillyShooter's profile

HillbillyShooter

5811 posts in 1759 days


#8 posted 10-01-2014 04:39 PM

Great blog! Thanks for sharing and thanks for the great photos.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View doubleDD's profile

doubleDD

5247 posts in 1510 days


#9 posted 10-01-2014 05:21 PM

Great of you to show the process of making these. I have it on my list to make one but not to replace the magnificent
one you made me. It could never be replaced. I looking at a much larger one to persuade piece to fit together. So I figured why not copy some of your talent in doing so. Thanks for the show and tell klaus.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View kiefer's profile

kiefer

4881 posts in 2133 days


#10 posted 10-01-2014 05:47 PM

Thanks John and I appreciate you looking in and it’s always nice to share .

Dave
Here is the larger version http://lumberjocks.com/projects/98733
Made the same way just a little more elaborate with the handle and wood choices but still only two cents .
John http://lumberjocks.com/HillbillyShooter
says horse leather is the best choice for the faces it lasts a lot longer .

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos

View gfadvm's profile (online now)

gfadvm

14940 posts in 2157 days


#11 posted 10-01-2014 08:08 PM

What a great tutorial! You made this look easy enough that I may have to attempt one.

Added to favorites

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View doubleDD's profile

doubleDD

5247 posts in 1510 days


#12 posted 10-01-2014 08:39 PM

Thanks Klaus. I added the big mallet to my favorites. I bet it will be a fun build. Just choosing the different wood is going to be cool.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View MrFid's profile

MrFid

805 posts in 1371 days


#13 posted 10-01-2014 10:00 PM

Very nice tutorial! Great pictures, and they came out lovely.

-- Bailey F - Eastern Mass.

View Mean_Dean's profile

Mean_Dean

5061 posts in 2614 days


#14 posted 10-02-2014 12:00 AM

Thanks for sharing your techniques with us! I love that “open” handle design of yours!

-- Dean

View DocSavage45's profile

DocSavage45

7708 posts in 2309 days


#15 posted 10-02-2014 12:01 AM

Klaus,

You did it! Thanks! This would take me waaaaaay more than 2 hours.

-- Cau Haus Designs, Thomas J. Tieffenbacher

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