|Project by Kelly||posted 03-06-2017 05:42 PM||512 views||1 time favorited||6 comments|
This copper clad mallet was built for the 2017 Lumberjocks Shop Made Tool Swap and was one of the several items I sent out.
The mallet is apple wood, from a friend’s Central Washington orchard, and is clad in thick wall copper pipe.
The tolerance I set for the turned apple wood was tight enough a kerf had to be cut in the head of the mallet in order to force the pipe over it.
Even with the kerf, the pounding required to press the pipe over the mallet head caused about 3/8” of the top of the pipe to fold over and press against the top of the mallet.
After the pipe was fully down over the mallet head, I continued to pound the folded portion of the copper pipe to smooth out hammer marks. Once I was satisfied I was as close as I could be to a smooth, rolled over top, I sanded the copper working from 150 grit to 320 grit. Then I took the mallet to the buffer and, using common red oxide, polished out the copper.
Once buffed, the copper, with its folded over top, looked like a well planed project. I didn’t. It was just a happy accident.
At this point, I cut a fine spline and pounded it into the kerf. In the end, I believe the copper pipe is well backed for pounding wood chisels. Only time and reports from its new owner will tell.