|Project by Bovine||posted 10-24-2010 04:01 AM||2286 views||4 times favorited||8 comments|
The wife and kids went out of town for the weekend and I got a little bored. I found a 9/4 slab of Walnut and decided to make a mallet with it. I’ve been getting into making my own tools lately—nothing like using tools you’ve made yourself to make other things. :)
This is my first attempt at making a mallet. I’m sure that within a year I’ll find several things wrong with it and make another one but you have to learn sometime, right?
The head and handle were both cut from 9/4 thick walnut. I didn’t have a plan per-se for the handle…I just marked where I like to hold a mallet and shaped it with sandpaper until it felt good in my hand. Where the handle would go through the head, I left it rectangular and pretty much untouched.
I first bored a hole through the head at the drill press (darned bits weren’t long enough!) then cleaned it up with a chisel. I must’ve done something right because the handle fit snugly into the hole. A little gentle persuasion with another mallet got the handle in.
Lastly, I glued on some leather to the striking surfaces of the mallet and finished the wood with Danish Oil. It was getting late when I finished, so tomorrow I’ll drive a couple brass pins through the side if I can find any. Otherwise I’ll use dowels.
Except for the leather pads, I didn’t use any glue. It is very tight and I hope with the pins it won’t move after use. The only thing I’m worried about is wood movement. Do you think it will blow out the head when the handle expands?
-- Kansas City, KS "Nothing is as permanent as a temporary solution"