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Roy's Mystery Mallet #1: Mallet - 1, Glen - 0

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Blog entry by pastorglen posted 911 days ago 5064 reads 5 times favorited 7 comments Add to Favorites Watch
no previous part Part 1 of Roy's Mystery Mallet series Part 2: Mallet - 1, Glen - 1 »

Dear “Saint” Roy,

I hate you.

Sincerely,
Mallet Muttering in Pennsylvania

———

Actually, I don’t hate Roy. And I’m not that disappointed as to this first attempt.

If you haven’t gotten the April 2012 issue of Popular Woodworkinghttp://www.popularwoodworking.com/apr12, you need to get it… now. They’ve got a great article by Roy Underhill on making the Mystery Mallet that you’ve been seeing around.

This actually is turning out to be a lot of fun. Before you point out the obvious, I know I shouldn’t have used poplar. But I just got this nice, thick piece of poplar and thought it would be a good place to start.

Although the joint isn’t totally tight, the concept is right on the money. I am very encouraged about this.

Here’s what I’ve learned:

1. Take extra time to lay this out with a sharp pencil or marking knife.
2. It helps to have multiple marking gauges, dividers, sliding t-bevels, etc. that you can designate for one set up at a time.
3. Mark the head of your mallet and the handle with sides (A, B, C, D) and TOP, BOTTOM.
4. If you get stuck, bring the wood in the house, get a drink of water, go to bed (it will probably be around 1 a.m.) and sleep on it. :-)
5. Use something other than poplar. (I have a thick piece of oak that I’ve set aside for something fun, like this.)

It will take a little time to get your head around these angles, slopes, joints, etc. These practice cuts have helped me get a better understanding of how this should work. Maybe tomorrow I’ll cut into the oak.

Maybe.

-- Glen, Pennsylvania, Colossians 3:23 "Whatever you do, work heartily, as for the Lord and not for men."



7 comments so far

View stefang's profile

stefang

12967 posts in 1970 days


#1 posted 911 days ago

I made a similar mallet a few years ago. Eventually the glue joints started popping apart and I had to use screws to keep it together. I got the plan from Woodworkers Journal quite a few years ago. I’m still using, but it won’t last much longer. I might be able to salvage the handle and the screws.. Mine only lasted about 8 years. Maybe the secret is the right type of glue. I hope you have better luck than I did. I hate things that don’t last!

Photobucket

-- Mike, an American living in Norway.

View pastorglen's profile

pastorglen

255 posts in 1326 days


#2 posted 911 days ago

Thanks for checking in, Mike.

When I first got into woodworking I didn’t have a mallet, and I didn’t really have the extra money to buy a “wooden hammer”—especially if this was just a passing interest. But I did have a box of hard maple flooring that someone was throwing out and gave me. A little work and planning and I glued up a simple mallet that has served me for several years.

I really like the shape of yours. That’s really what I was looking to make originally. So now I might have to make 2 mallets! Thanks for the picture.

-- Glen, Pennsylvania, Colossians 3:23 "Whatever you do, work heartily, as for the Lord and not for men."

View DocK16's profile

DocK16

1139 posts in 2723 days


#3 posted 911 days ago

Check this months Popular WW There is an article showing Roy making this mallet

-- Common sense is so rare anymore when you do see it, it looks like pure genius.

View Tim Dahn's profile

Tim Dahn

1467 posts in 2201 days


#4 posted 911 days ago

Sound like you have climbing up the learning curve Glen.

If you get stuck, bring the wood in the house, get a drink of water, go to bed (it will probably be around 1 a.m.) and sleep on it. HaHa…been there a few times.

Be sure to post the oak one.

-- Good judgement comes from experience and experience comes from poor judgement.

View pastorglen's profile

pastorglen

255 posts in 1326 days


#5 posted 910 days ago

Hey, DocK, that’s what got me a step farther toward the loony bin. :-) I’ve seen it hinted at for the past month or so, but it wasn’t until I got the magazine that the real planning got underway.

Thanks, Tim. And the oak is already on my bench waiting for the process to begin.

:-)

-- Glen, Pennsylvania, Colossians 3:23 "Whatever you do, work heartily, as for the Lord and not for men."

View rance's profile

rance

4130 posts in 1796 days


#6 posted 894 days ago

I drew one up in SketchUp a few months back and am dieing to try it out. I’ve not seen the article. I’ll try to do it without it first. Thanks for posting, and let us see the Oak one when you finish it.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View planeBill's profile

planeBill

478 posts in 1045 days


#7 posted 870 days ago

Extremely neat project. Went straight to my fav list. Thanks for sharing this. I have a big chunk of hophornbeam just for this.

-- I was born at a very young age, as I grew up, I got older.

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