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Kiefers Little Tapper build

8K views 25 replies 19 participants last post by  whistlingwoodies 
#1 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
 

Attachments

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#2 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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!
 

Attachments

#3 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#4 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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
 

Attachments

#5 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#6 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#7 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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 .
Wood Ruler Rectangle Wood stain Hardwood


Klaus
 

Attachments

#8 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#9 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#10 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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.
 

Attachments

#11 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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 .
 

Attachments

#12 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Added to favorites
 

Attachments

#13 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
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.
 

Attachments

#14 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#15 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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

Attachments

#16 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Klaus,

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

Attachments

#17 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Good lesson in building the Little tapper. Iʻve got enough scrap … might have to just build me one too. Thanks for sharing.
 

Attachments

#18 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
This is a beautiful tool and a great addition to your shop.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com
 

Attachments

#19 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Certainly a unique and attractive design .Thanks for the interesting blog Klaus.
 

Attachments

#20 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Great project and Blog. Thx for taking the time.
 

Attachments

#21 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
I started on a pair today and so far have 6 hours in them and had to modify the plans to fit my lack of skill level. (or lack of same)

Got em clamped and glued so we'll see what I have tomorrow…......
 

Attachments

#22 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
That sounds good Andy and you are on your way .
Lets see what you made tomorrow , be interesting what your design looks like .

Klaus
 

Attachments

#23 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Thanks all and it looks like there is a need by many for a little tapper .
I find it a lot of fun to make them and they are all just a little different in one way or another which keeps it interesting .
Hope to see some different ones here on LJ's .

Klaus
 

Attachments

#24 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Very nicely detailed how-to. Thnx Klaus.
 

Attachments

#25 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Wauuuuuuuuuuuuuuu just went through this blog and kind of regret I did not do it earlier, might have inspired me to be more creative on my handle.
Took the freedom to mention you in a dead blow mallet project I just made, since I think you set a new mallet standard.
Best thoughts,
Mads
 

Attachments

#26 ·
Kiefers Little Tapper build

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 .
Wood Tool Hardwood Wood stain Flooring

Next I mark out the centre layer of the head and cut it into three pieces using my sled on the table saw .
Wood Floor Flooring Wood stain Hardwood

Wood Tool Font Wood stain Office ruler

Rectangle Wood Flooring Floor Wood stain

Wood Rectangle Wood stain Floor Flooring

Wood Rectangle Wood stain Hardwood Brick

Wood Road surface Symbol Composite material Cross

Wood Tool Table Hardwood Lumber

Wood Flooring Floor Rectangle Wood stain

Wood Rectangle Flooring Floor Wood stain

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 .
Brown Wood Rectangle Flooring Floor

Hand tool Metalworking hand tool Tool Wrench Wood

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 .
Wood Flooring Hardwood Gas Wood stain

Musical instrument Wood Tool Hand tool String instrument

Plane Hand tool Wood Scrub plane Tool

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.
Wood Flooring Floor Wood stain Hardwood

Here are the handle scales glued on and the wedges in stalled .
Wood Automotive tire Hardwood Gas Chair

Wood Slip joint pliers Electrical wiring Wood stain Hardwood

Wood Bumper Gas Automotive exterior Auto part

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 .
Saw Wood Tool Hand tool Handheld power drill

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 .
Wood Flooring Hardwood Wood stain Plywood

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 .
Wood Wood stain Flooring Hardwood Rectangle

Wood Floor Table Gas Hardwood

A special little insert I choose for this one and the leather faces getting glued on .
Musical instrument Wood Hardwood Door Varnish

Wood Flooring Floor Wall Brick

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
Thank you for the step by step directions.
 

Attachments

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