New Mallet Head

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Project by Jim Jakosh posted 07-07-2016 01:52 AM 1005 views 0 times favorited 20 comments Add to Favorites Watch

I made a mallet for my lathe at least 5 years ago and it split out when I hit something hard last year( second photo). I finally took the time to replace the head and I saved the mesquite handle because it was still okay. I wanted to have brass rings around the ends of the head to keep it from ever splitting again but that was $32 a foot plus shipping. When shopping for steel at Central Iron on Tuesday, I found a short stainless steel pipe exactly the size I needed and made the rings out of it. The third shot shows the PVC loader I made to pound the rings on. They have about an .008” press fit and no glue. The last shot shows the end of the head that I coated with West System epoxy to solidify those end grain fibers. I am not sure what kind of wood it is but LJ Doug Scott brought me a 4×4 of it and it is real heavy and dense grain.
This one should outlast me!!

It is finished with clear lacquer.

cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

20 comments so far

View lew's profile


11838 posts in 3588 days

#1 posted 07-07-2016 01:55 AM

Sweet! Much nice than the old banger I have!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Blackie_'s profile


4788 posts in 2346 days

#2 posted 07-07-2016 01:59 AM

Nice one Jim

-- Randy - If I'm not on LJ's then I'm making Saw Dust. Please feel free to visit my store location at

View kiefer's profile


5579 posts in 2500 days

#3 posted 07-07-2016 02:00 AM

That should last and get attention !
Nice job with the SS rings .


-- Kiefer

View Druid's profile


1662 posts in 2628 days

#4 posted 07-07-2016 02:51 AM

Sure looks good to me. Nice touch with the stainless rings.

-- John, British Columbia, Canada

View doubleDD's profile (online now)


6826 posts in 1876 days

#5 posted 07-07-2016 02:51 AM

Great job with the mallet head Jim. That stainless should hold it forever. Looks super.

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

View tyvekboy's profile


1701 posts in 2846 days

#6 posted 07-07-2016 03:03 AM

Beautiful mallet.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View hoss12992's profile


3967 posts in 1726 days

#7 posted 07-07-2016 03:21 AM

Very nice. Great job. Much nicer than my old mallets.

-- The Old Rednek Workshop

View Cliff 's profile


1152 posts in 1557 days

#8 posted 07-07-2016 04:16 AM

Beautiful Job on restoring the Mallet Jim…..Nice Work….The stainless steel rings turned out well. I must remember your PVC way to pound on the rings. I understand the Brass Situation regarding cost, I don’t know how many times I have scanned the net looking for Brass Tubing and sometimes the freight is more costly than the goods…...I am still looking. Many years ago there was a Metal Merchant in my town and he always had Barrels of scraps that folk could pick through for Jobs around the home or Hobby Work….but these days of political correctness this is not allowed as someone might hurt themselves???? Oh for the simple days!!!!!!
Great Project Jim.




-- Cliff Australia : Snoring is good. It blows away all the Sawdust.

View Tooch's profile


1655 posts in 1709 days

#9 posted 07-07-2016 11:55 AM

looks great Jim, nice save

-- "Well, the world needs ditch-diggers too..." - Judge Smails

View majuvla's profile


11183 posts in 2700 days

#10 posted 07-07-2016 05:19 PM

You can give it as judge mallet, looks very beutiful.

-- Ivan, Croatia, Wooddicted

View Jim Jakosh's profile

Jim Jakosh

19751 posts in 2938 days

#11 posted 07-07-2016 10:07 PM

Thank you all for the nice comments. It is on the lathe and I was banging with it today. I like it because it is heavier than the old one.

cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View HillbillyShooter's profile


5811 posts in 2125 days

#12 posted 07-08-2016 12:12 AM

Great job—especially the SS bands.

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

View Jim Jakosh's profile

Jim Jakosh

19751 posts in 2938 days

#13 posted 07-08-2016 03:26 AM

Thanks, John. I think I like those SS bands as much as brass ones!!


-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View BobWemm's profile


2343 posts in 1759 days

#14 posted 07-08-2016 08:01 AM

Looks very robust. Like you said Mate, it should outlast you.

-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View Roger's profile


20874 posts in 2637 days

#15 posted 07-08-2016 09:17 PM

A very classy adjustment tool

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

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