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David Barron inspired Mallet

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Project by Troy Cleckler posted 04-21-2015 03:01 AM 3070 views 6 times favorited 14 comments Add to Favorites Watch

Ever since I’ve seen David Barron use his palm mallet I’ve wanted one. Being the cheap one that I am, I found a piece of brass that come out of a tractor differential the perfect size, 1-1/2”x4”. I cut an inch off of it, mounted it in my wood lathe and used an angle grinder with a paint stripper pad to cut the grooves out and shape the rounded over end.
I sanded through 2000 grit paper and it polished up good. It was a little tricky turning it around in the chuck without maring the finish. I used some leather and it gripped good enough though I did have to tap it several times with it on low speed, to get it true.
Handle is turned from cherry with black walnut spline. Still need to drill and put a brass pin through it because the head is heavy and I can turn it if I try. It feels good taping on a chisel and fits my hand well. I think it’ll get a lot of shop time.
I changed the handle design to fit my hand better. see last pic

-- Troy. - Measure twice, cut once and fill the gaps....





14 comments so far

View woodcox's profile

woodcox

1576 posts in 1479 days


#1 posted 04-21-2015 03:32 AM

Nice work Troy. I’m going to try a little brass tapper soon, thanks for the leather tip.

-- "My god has more wood than your god" ... G. Carlin.

View siavosh's profile

siavosh

674 posts in 1338 days


#2 posted 04-21-2015 06:10 AM

Very cute tear drop shape, must be great for delicate work.

-- http://woodspotting.com/ -- Discover the most interesting woodworking blogs from around the world

View TechTeacher04's profile

TechTeacher04

326 posts in 999 days


#3 posted 04-21-2015 11:47 AM

Your design is very similar to the Glen Drake Tools mallets. I like the generous size of the mallet head and handle. I am sure it will produce a powerful strike.

View Troy Cleckler 's profile

Troy Cleckler

384 posts in 839 days


#4 posted 04-21-2015 12:58 PM

weighed it this morning and it’s 1.2 lbs.

-- Troy. - Measure twice, cut once and fill the gaps....

View GravyBones's profile

GravyBones

43 posts in 600 days


#5 posted 04-21-2015 08:40 PM

I like this. This is totally awesome. Simple in form and elegant.

-- http://www.WaveFish.com

View SteveGaskins's profile

SteveGaskins

647 posts in 2054 days


#6 posted 04-21-2015 09:23 PM

I’ve always liked this mallet, too. But like you, I’ve always said I would just build one…..still saying that. Great job and thanks for the inspiration to get a move on it.

-- Steve, South Carolina, http://www.finewoodworkingofsc.com

View Troy Cleckler 's profile

Troy Cleckler

384 posts in 839 days


#7 posted 04-21-2015 09:40 PM

I need to pin it because the head will turn. I think that I may drill it and use wood instead of brass. That way I can drill it out easier if ever i want to change the handle in form or wood choice. It should serve the purpose.

-- Troy. - Measure twice, cut once and fill the gaps....

View larryw's profile

larryw

330 posts in 2129 days


#8 posted 04-22-2015 01:42 AM

Love the mallet Troy., I’ve considered making one of these myself. I’m also impressed with with all the cool things that David barron comes up with. He’s an excellent craftsman and appreciates fine craftsmanship produced by others, I think you would make him proud.

-- "everything is beautiful, but not everyone sees it" ~confucius-551-449 b.c.~

View Troy Cleckler 's profile

Troy Cleckler

384 posts in 839 days


#9 posted 04-22-2015 02:35 AM

Awe man, just got picked for editors choice and I’ve just got through changing the handle. I decided to change it because the original seemed short and a little too big round. I cut another chunk off my Zircote stump and come up with a new better fitted handle. I took the time to pay closer attention to the wedge to make it really tight, locked it in with a drilled hole and turned down a piece of black walnut to plug it with. It’ll be easier to drill out if ever I need to replace the handle. Hope this isn’t a bad thing after being chose editors choice.
Let me know if you like it better, I sure do.

-- Troy. - Measure twice, cut once and fill the gaps....

View Frank Doyle's profile

Frank Doyle

42 posts in 2864 days


#10 posted 04-22-2015 11:58 AM

I for one like the newer and plan to steal your idea, thanks

-- Frank

View Troy Cleckler 's profile

Troy Cleckler

384 posts in 839 days


#11 posted 04-22-2015 12:07 PM

No Stealing! But you’re welcome to borrow whatever you want. Ha!
That’s what these forums are all about seeing things that we like and bouncing ideas off one another. I’ve learned a lot poking around this forum.

-- Troy. - Measure twice, cut once and fill the gaps....

View NormG's profile

NormG

5510 posts in 2471 days


#12 posted 04-27-2015 02:25 AM

Very nice mallet, very useful to have in this size

-- Norman - I never never make a mistake, I just change the design.

View ztifpatrick's profile

ztifpatrick

10 posts in 2160 days


#13 posted 04-29-2015 09:15 AM

Nice looking mallet, it makes you want to pick it up! How thick is it at the bottom? I’m a fan of David Barrons’ too.

View Troy Cleckler 's profile

Troy Cleckler

384 posts in 839 days


#14 posted 04-29-2015 10:37 AM



Nice looking mallet, it makes you want to pick it up! How thick is it at the bottom? I m a fan of David Barrons too.

- ztifpatrick


I’ll have to measure to know for sure. I based it on how it felt. I would stop the turning frequently to check how it felt in my grip. I like the proportions but more importantly I like the way it fit and feels in hand. If the chisels are out this will be on the bench.

-- Troy. - Measure twice, cut once and fill the gaps....

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