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Roy's Mystery Mallet #2: Mallet - 1, Glen - 1

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Blog entry by pastorglen posted 03-10-2012 02:42 AM 2497 reads 2 times favorited 5 comments Add to Favorites Watch
« Part 1: Mallet - 1, Glen - 0 Part 2 of Roy's Mystery Mallet series Part 3: Dressed and Ready for Work »

Dear Saint Roy,

I like you a lot more this week. Lots.

Sincerely,

Mallet Boy in PA

———————
If you haven’t gotten a copy of the April 2012 issue of Popular Woodworking, do it today. That’s where this insanity all got started. But I’m telling you, I never could have launched into this if it weren’t for that article. They do a great job. Check them out.

The second attempt with the hardwood turned out to be much better. Doing a practice run with the poplar was a great idea and helped me figure out the angles and such.

As I wrote in the previous blog, I also used my marking knife for nearly every cut. When I couldn’t see the mark it was making, I used a fine-tip pen. That helped out, too. Using two dedicated marking gauges was also helpful. Same with the sliding t-bevel.

I’m pretty happy with the results.

The joints were much better, too.



Some things I learned:

1. Perfection doesn’t come the first time, and that’s okay. The second time is usually going to be better, so give your project a second attempt.
2. When I was cutting the sides of the mallet head, I used my chisel to cut a starter-groove for my saw. That helped create nice, crisp joints. A must for this project.
3. The hardwood (which I think is either oak or ash—it was a hand-me-down) was easier to work with than I expected.
4. I had my boys help me with the assembly. They were totally into it and excited with the results. More generational woodworking.
5. I test fit this and re-measured just about every way I knew possible. When I was ready to “bite the bullet,” I glued it up real good, and started assembly. YOU WILL NOT BELIEVE how hard I had to hit this to get it to go together. Even still, the fit is pretty much right on.
6. The only change I would make is in the assembly. As you can see from the detail of the top of the mallet head, there is some discoloration on the right side. I didn’t realize that my mallet head was bottomed out on the vise, and I sort of crushed the end grain on that side. Not a big deal, but I would be more careful about that if I were doing it again.

I’ll add some finish and include a closing picture later.

Thanks for looking in.

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



5 comments so far

View dpow's profile

dpow

462 posts in 1565 days


#1 posted 03-10-2012 05:11 AM

Looks good Glen. That should serve you well. Thanks for sharing .

-- Doug

View Tim Dahn's profile

Tim Dahn

1474 posts in 2286 days


#2 posted 03-10-2012 01:37 PM

Mallet boy you should be proud of this! Very nice, the “practice poplar ” one definitely helped you figure out the joints. looking forward to the pics with the finish on it, you will get many years of use out of it.

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

View Dave's profile (online now)

Dave

11198 posts in 1561 days


#3 posted 03-12-2012 01:38 AM

Very nice and very impressive.

-- Superdav "No matter where you go - there you are." http://chiselandforge.com

View yrob's profile

yrob

340 posts in 2374 days


#4 posted 03-12-2012 01:52 AM

Very good job. I did one too but I had an advantage. I did it in the shop with Roy so his guidance helped me to not have it break the first time.

-- Yves

View pastorglen's profile

pastorglen

258 posts in 1412 days


#5 posted 03-12-2012 01:37 PM

Thanks for posting, everyone.

yrob – GOOD FOR YOU!! That’s a nice one, too. And I went into the first one knowing it was a practice. So it was a good learning opportunity. The second one was with the good stuff. And because the head is hardwood, too, it should last a while.

As much as I enjoyed making it on my own, in my shop, with Roy’s instructions nearby, I would have much rather joined your class in North Carolina. :-)

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

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