Project Information
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 Williams
HammerThumb
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 Williams
HammerThumb