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2018 Mallet/Hammer Swap *Damascus Steel*

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Project by KelleyCrafts posted 07-19-2018 10:39 PM 1758 views 4 times favorited 29 comments Add to Favorites Watch

All, here is my entry for the 2018 Hammer swap. I decided to actually make a real live 2lb hammer for the swap and a little damascus steel detail hammer.

Here is the steel I started with and some of my steps.


The damascus hammer ended up being 27 layers of 15N20 and 1095. The handle is zebrawood.

The steel hammer was made from 1045 steel and the head weighs right around 2lbs. The handle for this one is hickory so it can take a solid beating.

Thanks for looking!!

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools





29 comments so far

View bobasaurus's profile

bobasaurus

3544 posts in 3381 days


#1 posted 07-19-2018 10:54 PM

These came out great, Dave. What is your etching process for the damascus? Ferric chloride? Again, I’m impressed with your ability to punch a centered hole so nicely in big stock. Do you mark the center on the round first with a cold punch? Are those flats formed during the punch, or are you flattening the round first?

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View palaswood's profile

palaswood

1055 posts in 1949 days


#2 posted 07-19-2018 11:01 PM

Amazing mallets! Im pretty sure you got the best reactions on your mallet. I want to see more of the process. Maybe write a blog about it?

-- Joseph, Irvine CA, @palas_woodcraft on Instagram

View Woodknack's profile

Woodknack

12430 posts in 2577 days


#3 posted 07-19-2018 11:16 PM

Show off! Just kidding, beautiful hammers Dave.

-- Rick M, http://thewoodknack.blogspot.com/

View EarlS's profile

EarlS

1893 posts in 2545 days


#4 posted 07-19-2018 11:16 PM

Your pictures show your work off much better than mine did. I recall seeing the twisted steel on the swap thread and wondered what it would be. Well now I’m the proud recipient of your excellent craftsmanship.

BTW – Do I need to treat them with any surface protectant?

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

View Dave Polaschek's profile

Dave Polaschek

2821 posts in 779 days


#5 posted 07-19-2018 11:24 PM

Very nice work, Dave. Course being in Arizona, it’s not like you had to do much more than set the steel out in the sun until it got runny, right? ;-)

-- Dave - Minneapolis

View KelleyCrafts's profile

KelleyCrafts

3301 posts in 936 days


#6 posted 07-19-2018 11:41 PM



Amazing mallets! Im pretty sure you got the best reactions on your mallet. I want to see more of the process. Maybe write a blog about it?

- palaswood

I don’t know Joseph, big dogs cocobolo got a big reaction. I know I thought that wood turned out awesome.

Maybe I’ll blog about it if there’s interest but it’s a woodworking site so I’m not sure it would fit in well.

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools

View KelleyCrafts's profile

KelleyCrafts

3301 posts in 936 days


#7 posted 07-19-2018 11:42 PM


Your pictures show your work off much better than mine did. I recall seeing the twisted steel on the swap thread and wondered what it would be. Well now I m the proud recipient of your excellent craftsmanship.

BTW – Do I need to treat them with any surface protectant?

- EarlS


Thank you Earl!

That isn’t stainless steel Earl so some way or oil as needed would be good.

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools

View KelleyCrafts's profile

KelleyCrafts

3301 posts in 936 days


#8 posted 07-19-2018 11:43 PM

Thanks Dave and Rick I appreciate your comments.

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools

View KelleyCrafts's profile

KelleyCrafts

3301 posts in 936 days


#9 posted 07-19-2018 11:53 PM



These came out great, Dave. What is your etching process for the damascus? Ferric chloride? Again, I m impressed with your ability to punch a centered hole so nicely in big stock. Do you mark the center on the round first with a cold punch? Are those flats formed during the punch, or are you flattening the round first?

- bobasaurus

I use ferric chloride Allen. With this little hammer I think I’ve figured out what I’ll run with going forward. My knife I made earlier could definitely get a new cleaner etch. Here’s the process I followed:

Sand to 1200, etch for 20 minutes in 50/50 solution.

Sand to 2000, etch for 3 minutes

Sand lightly with 2500 until you get the desired “pop”.

As for the hammers….I’ve made a bunch of the big ones now and I’ve tried so many ways to do the round steel since I can’t seem to find square bar stock in 1045 or 4140. It’s a dance man. I don’t cold punch anymore since it’s a pain on round stock. Once it’s hot I pull it out and put a ruler up to it and punch in the middle length wise to get them even. From there I put it right back in and tap very light flats in it when it comes out. Once I know it’s good I just slam the hammer as hard as I can each time. By the time my eye punch is 1/4” in I have slightly bigger flats and a hole to register in. Then I just hit it a few time and turn it 180 after a few whacks. I go about 3/4 of the way through then I flip it over and go from the other side doing the same thing. On my own it takes me about two hours for the eye in a hammer that size. If my kid is around I can get him to hold it and I can really whack it. I can cut 45 minutes off. After that I shape the rest of the hammer.

The shape I came up with is just different then the other I see. I wanted my own “style”. So my newer hammers look like that now.

Anymore questions feel free man.

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools

View GR8HUNTER's profile (online now)

GR8HUNTER

5099 posts in 910 days


#10 posted 07-19-2018 11:57 PM

the 2 lb is a very nice but the Damascus is one top notch very nice little Wacker …. WOW .. GREAT JOB :<))

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View jeffswildwood's profile

jeffswildwood

3590 posts in 2175 days


#11 posted 07-20-2018 01:01 AM

Super job Dave! That’s one that will last forever. That damascus is just awesome!

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View JayT's profile

JayT

5957 posts in 2408 days


#12 posted 07-20-2018 01:14 AM

Wicked nice, Dave.

Forging looks like a rabbit hole I could easily go down. Not enough time in the day, however, so I’ll have to resist.

-- In matters of style, swim with the current; in matters of principle, stand like a rock. Thomas Jefferson

View TheFridge's profile

TheFridge

10700 posts in 1683 days


#13 posted 07-20-2018 01:36 AM

I would definitely bang those hammers. Fo sho.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View KelleyCrafts's profile

KelleyCrafts

3301 posts in 936 days


#14 posted 07-20-2018 02:19 AM

Thank you guys!

I have a long way to go JayT. It’s a fun ride though!

-- Dave - http://kelleycrafts.com/ - pen blanks - knife scales - turning tools

View woodcox's profile

woodcox

2156 posts in 2209 days


#15 posted 07-20-2018 04:20 AM

Beautiful work there,Dave.

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

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