|Project by Hammerthumb||posted 07-01-2014 10:12 PM||984 views||4 times favorited||15 comments|
This mallet was made for LJ buddie PAJA for the 2014 mallet swap. And here is the letter I included with the mallet:
Mallet Swap 2014
Paul – aka PAJA,
Here is the mallet that I made for you. I hope you enjoy it. The mallet is made from some old French White Oak flooring that I had lying around for a few years. It was a rustic grade but I selected the pieces carefully to avoid knots.
The mallet head is laminated from several pieces. I think this makes for a stronger assembly and should not split in use. I did not use a traditional method of wedges for attachment of the head. It is very difficult to describe as I have actually made some dovetail shapes at the top of the handle that keep the head and handle from moving. I had great concern about wood movement as I live in the desert and the moisture content of the wood is below 5%. If the wood expands a little, it should only make the head tighter on the handle, but allows for movement only towards the top of the mallet. I left the protrusion of the handle at the top of the head at approximately 3/16” and any wood movement should not exceed this dimension. I will post pictures of the assembly process after the swap opening so you have a better idea of what is inside the mallet. I also used some brass pins to help keep the laminations together, and for added weight. I used urethane glue for assembly as I think the foaming action of the adhesive provides some cushion for shock absorption and will not de-laminate due to impact.
I faceted the edges to reduce the chance of an off hit damaging any edges. I think that it also adds to the looks of the mallet.
This mallet is a nice size and can be used for heavy chopping of mortises, as well as light tapping. I turned, and then hand shaped the handle. It fits comfortably in my hand, and the weight and balance feels good.
I elected to keep this mallet simple and functional (after all, it’s just a mallet). I hope it gives you many years of rugged service
I hope you don’t mind that I stamped the bottom of the mallet with HT for HammerThumb. At least you will always be able to remember where it came from.
Good luck and happy wood working.
-- Paul, Las Vegas