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Simple Mallet

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Project by christherookie posted 01-28-2010 04:16 PM 1776 views 1 time favorited 10 comments Add to Favorites Watch

This is my first complex woodworking project (albeit simple to most of you). The tool is made from a single piece of 1×4 oak.

I don’t have a table saw and I didn’t want to spend the whole time bent over with my foot on one end of a board running my circular saw. Not fun on the old back. Therefore, I mortised out the top popular board in the T-form you see in the last two photos. Once I mortised it out, I drilled two pilot holes and then drilled out a bit to countersink two screws. Placing this rig (is there a name for it?) in my vise, I was able to clamp my oak board to it and run my circular saw while standing upright. I’d also clamp my square to the board that was offset to the line I was cutting and could therefore make straight cuts every time.

T-form in place, it was a matter of cutting out the desired pieces and then laminating them together. I used a common design for the mallet with three layers. The center layer having two small pieces of oak and the handle through the middle. I bore out holes in the two smaller pieces and added fishing weights (lead). Then I laminated everything together with titebond and used three clamps to hold it all together.

Once it had sat for 24 hours, I sanded down the mallet, added the eyescrew for hanging, and hit it with boiled linseed oil.

The head has a 5 degree angle on it. Ok, it has a 5ish degree angle on it. :)





10 comments so far

View SgtSnafu's profile

SgtSnafu

957 posts in 1925 days


#1 posted 01-28-2010 04:21 PM

Nice mallet – I have been thinking of making a dead blow mallet, but may build one like this first.

Thank you for sharing

-- Scotty - aka... SgtSnafu - Randleman NC

View PurpLev's profile

PurpLev

8476 posts in 2302 days


#2 posted 01-28-2010 04:35 PM

looks great! now I really should go ahead and make one too… still using a scrap piece of 4×4…

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View christherookie's profile

christherookie

45 posts in 1700 days


#3 posted 01-28-2010 04:41 PM

PurpLev: Thanks for your tips on building it.

View PurpLev's profile

PurpLev

8476 posts in 2302 days


#4 posted 01-28-2010 04:52 PM

my pleasure. it really came out great. how do you like using it?

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View christherookie's profile

christherookie

45 posts in 1700 days


#5 posted 01-28-2010 05:09 PM

So far, I’ve used it to threaten the neighbor kids, the neighbor’s dog, the television…ah, just kidding. The measuring gauge I asked about yesterday will be the first project in which it will get used. The weight and size seem perfect. That reminds me, I’ve got to go chisel shopping in the next few days.

View a1Jim's profile

a1Jim

112087 posts in 2230 days


#6 posted 01-28-2010 06:22 PM

Looks good

-- http://artisticwoodstudio.com Custom furniture

View Jim Crockett (USN Retired)'s profile

Jim Crockett (USN Retired)

852 posts in 2386 days


#7 posted 01-29-2010 04:19 AM

Nice job! And you did that with a circular saw – pretty amazing!

Jim

-- A veteran is someone who, at one point in his/her life, wrote a blank check made payable to "The United States of America," for an amount of "up to and including his/her life".

View Karson's profile

Karson

34876 posts in 3054 days


#8 posted 01-31-2010 08:14 PM

Nice mallet and great thinking on making a jig to help you cut it.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View bobkberg's profile

bobkberg

363 posts in 1727 days


#9 posted 02-17-2010 10:43 PM

To echo Karson above, good thinking. Necessity is truly the mother of invention. If you’re tight on money or space, you could probably make (if not buy) a “conversion kit” to allow your circular saw to be used as a table saw. It could be mounted for use on saw horses or some such, and then taken apart to be stored if space is the problem.

-- Bob www.singularengineering.com - A sideline, not how I earn a living

View christherookie's profile

christherookie

45 posts in 1700 days


#10 posted 02-17-2010 11:15 PM

Thanks, I’ll check out the conversion kits.
For now, I have had a stroke of good luck. I was recently gifted with a new Dremel 4000 and a bunch of attachments. Much to learn with it.

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