LumberJocks

Copper Clad Carving Mallet

  • Advertise with us
Project by Kelly posted 03-06-2017 05:42 PM 463 views 1 time favorited 6 comments Add to Favorites Watch

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.





6 comments so far

View Andre's profile

Andre

1157 posts in 1379 days


#1 posted 03-07-2017 12:28 AM

That is a fine looking beating stick! May be a bit to pretty?

-- Lifting one end of the plank.

View Andy's profile

Andy

226 posts in 400 days


#2 posted 03-07-2017 12:37 AM

That is a nice mallet and a good design too. A piece of brass pipe could also be good for one of these if you wanted a heavier one.

-- Andy Smith https://www.etsy.com/shop/xrayhardwoods

View Kelly's profile

Kelly

1366 posts in 2517 days


#3 posted 03-07-2017 02:13 AM

Good tip, Andy. I happened to have the copper pipe on hand. With the “I’m cheap” thing in mind, I cringe and the thought of the price of brass, however.

This one actually has some VERY good heft to it. Some of that is thanks to the apple wood, but the thick wall copper seems to offer some theft too.


That is a nice mallet and a good design too. A piece of brass pipe could also be good for one of these if you wanted a heavier one.

- Andy


View Kelly's profile

Kelly

1366 posts in 2517 days


#4 posted 03-07-2017 02:14 AM

We were wondering on that. It’s going to lose it’s shine pretty quick when it starts getting smacked against the end of a chisel. What the hay though, we drive nice cars in the mud…..

The apple wood was stolen from a buddy’s burn pile (he got over it) and was very dry. I had to epoxy part of the handle. Without the copper, and at the diameter of the mallet, it would have worked, but may have splintered over time. The copper gave the smaller footprint some heft.

I need to build myself one (I’ve made several more and given them away too).

Oh, and all the above aside, “yeah.”


That is a fine looking beating stick! May be a bit to pretty?

- Andre


View helluvawreck's profile

helluvawreck

24791 posts in 2439 days


#5 posted 03-07-2017 12:48 PM

This is a magnificent carving mallet and a fine addition to any shop. Congratulations.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View bondogaposis's profile

bondogaposis

4208 posts in 1924 days


#6 posted 03-07-2017 01:47 PM

This is a really nice, innovative swap item.

-- Bondo Gaposis

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

HomeRefurbers.com