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Project by kiefer posted 02-25-2015 09:36 PM 4485 views 15 times favorited 20 comments Add to Favorites Watch

This is the latest addition to the original open handle design mallet which I came up with some time ago and has worked out very well .
This one is a dead blow mallet with a five layer head design ,the center layer is the core to which the open handle attach├ęs just like in my other mallets and here is a link to a blog I did on the construction details .
The layers (two ) adjacent to this are the chambers for the steel shot and are made up of top and bottom strips and end caps and then the two outside layers .There are two end caps and covered with 2 ply leather .
The chambers are filled about three quarter full with 4.5mm steel shot.

A little sketch that may help .
The open design of the handle which is laminated from two layers (each side )(also see blog ) of hickory for extra strength and adds in absorbing shock in addition to the steel shot used to creat the dead blow.
I figured by making the chambers long it would give a a greater impact force .
I gave the mallet a little trail run today and it seems to pack a nice wallop and works great on my wooden hold downs .
Dim. are 12” x6” X 1/2” with a slight angle to the mallet face.
The wood is Jatoba /maple /walnut and hickory .

The hold downs have been modified and made stronger by adding a nut on the underside in one design upgrade and in the other upgrade design I added two nuts and washers . (see Picture ) I had no problem with the original design but someone came along and used a 5 LBS steel mallet to drive the hold down tight and popped the top off .(IDIOT )

Thanks for taking a look and comments are always welcome !


-- Kiefer

20 comments so far

View HillbillyShooter's profile


5811 posts in 2494 days

#1 posted 02-25-2015 11:01 PM

As always, great job. I’m still using a similar one (albeit lacking a fancy handle) I build in 2002, with the same horse hide faces originally installed.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View mafe's profile


11741 posts in 3291 days

#2 posted 02-25-2015 11:40 PM

Way to go. that’s a sexy dead blow.
Love it.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View madts's profile


1873 posts in 2542 days

#3 posted 02-25-2015 11:44 PM

Not too shabby Klaus. I think that you have shamed me into making one.

-- Thor and Odin are still the greatest of Gods.

View doubleDD's profile


7895 posts in 2245 days

#4 posted 02-26-2015 12:05 AM

Definitely a perfect design with the oval head. It looks so well balanced just looking at the picture. I would like to make one but I still have one made out of logs from years back and just can’t part with it. Your design and inspiration has helped me a lot with mine and I thank you for that. I’m just wondering what kind of mallet you will come up with next.
Of course I need to ask the weight of the dead blow. Thanks Klaus.

Oh, was it you’re new helper that used the 5lb. mallet on the bench dogs? It’s hard to get good help these days. lol.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View  woodshaver Tony C   's profile

woodshaver Tony C

6226 posts in 3555 days

#5 posted 02-26-2015 12:12 AM

I wish I could reach right into your photos there and grab one of those Beautiful crafted dead blow mallets. I know I know make my own!
But they are made by one of the finest craftsman I know!
OK…All kidding aside, they are great looking Mallets! Nice work Klaus.
Glad you got the hold down fixed, live and learn

-- St Augustine FL, Experience is the sum of our mistakes!

View Roger's profile


20952 posts in 3006 days

#6 posted 02-26-2015 12:12 AM

Nice attitude adjuster tools, and the wood combos are way cool.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

View Andre's profile


2217 posts in 2008 days

#7 posted 02-26-2015 12:30 AM

Very nice, now I guess a dead blow is on the to do list! Just so happens I came across a 4/4 hickory board a while back. Has to wait, need to build a small shelf for a TV to sit on, and maybe get that shop finished!!!

-- Lifting one end of the plank.

View Mean_Dean's profile


6902 posts in 3349 days

#8 posted 02-26-2015 12:51 AM

You really are developing these mallets into a fine art!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View DocSavage45's profile


8724 posts in 3045 days

#9 posted 02-26-2015 03:31 AM


Any more mallets and you will have to change your name to Thor. LOL!

I bow to the master! nice work sir.

-- Cau Haus Designs, Thomas J. Tieffenbacher

View MarkTheFiddler's profile


2068 posts in 2391 days

#10 posted 02-26-2015 04:12 AM

Klaus thank you very much for the specs on that stunning mallet.

I desperately need to build one. I’m thinking about the double strike I get when I’m upholstering the outside back or arms of a couch. We use tack strip to secure the fabric in a very crisp and well tailored line. I’d like to drive an entire section of tacks in one swing. Otherwise, the tacks can turn sideways, the tack strip can bend and the fabric can get marred.

Would that open handle design handle a really solid swing? I like the design but I think it would take forever to make one even remotely like yours. I’d hate for it to snap.

-- Thanks for all the lessons!

View Woodknack's profile


12431 posts in 2582 days

#11 posted 02-26-2015 04:30 AM

Nice proportions.

-- Rick M,

View kiefer's profile


5622 posts in 2869 days

#12 posted 02-26-2015 04:39 AM

Thanks all for your comments and they are very much appreciated and make it worthwhile to post project and share some of the details and I hope it to be an inspiration .

Klaus .

-- Kiefer

View bushmaster's profile


3348 posts in 2485 days

#13 posted 02-26-2015 02:50 PM

Great workmanship and thoughtful design, your details provide food for thoght for many of us, My next mallet I had some ideas for a dead blow type. thanks for posting.

-- Brian - Hazelton, British Columbia

View TurnTurnTurn's profile


614 posts in 3311 days

#14 posted 02-26-2015 06:30 PM

Beautiful work. Thx for sharing, I may need to give this a try.

-- TurnTurnTurn

View hoss12992's profile


4091 posts in 2095 days

#15 posted 02-26-2015 07:52 PM

Another beauty. Great job buddy

-- The Old Rednek Workshop

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