|Project by ChrisJ||posted 01-23-2012 05:33 AM||1399 views||3 times favorited||4 comments|
It seems almost like making a wooden mallet is a rite of passage in the woodworking world, so here are mine. I used oak scrap and a little poplar. I doubt that those are the best woods for mallets but they’re what I had in the scrap bin. I originally was set to make one all oak but I figured that if I used poplar in the middle I could make two—and two is better than one. I got to use a few techniques I’ve never used: 1) I was trying what I think is called a “compound curve” on my bandsaw (cutting the curve on one plane then taping the cutoffs back on the piece then cutting the curve on the other plane). The cutting/taping/cutting system worked well but I jacked up one of the curves and ruined the handle. 2) Wedged through tenons. Even though the mortise is made up of two pieces of wood. 3) Grain filling. I used info from this article. They were pretty fun to make, both finished with my current favorite, Danish Oil.
Pic 1: Both mallets, crossed in such a way as to look super-cool.
Pic 2: Mallet 1. My favorite. The bottom curve is messed up a little—gives it character, right? It’s just under 19 oz., face cut to 3 degrees. Grain filled using the paste filler method—I think it worked better.
Pic 3: Mallet 2. I think I like this handle better—it’s modeled after my dead blow mallet and feels pretty good in the hand. Just over 20 oz., face cut to 5 degrees. Grain filled using the oil/sanding dust slurry method.
Pic 4: Tops of the mallets, showing the wedged tenon.
Pic 5: Both mallets. Not crossed and not as cool as pic 1.