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Designed a Mallet - Build a Dead Blow Hammer - Got a Lethal Weapon

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Project by steliart posted 06-30-2013 07:02 PM 2354 views 7 times favorited 11 comments Add to Favorites Watch

Designed a Mallet – Build a Dead Blow Hammer – Got a Lethal Weapon

For some time now I wanted to build myself a mallet. The ones I have in my tool cabinet are commercial rubber mallets which they are ok for my woodworking needs, but still I wanted a nice strong one that could give a blow.

From all the designs/plans I’ve seen the Woodsmith Shop Notes one looked nice enough because it allows the use of different wood species and that’s exactly what I wanted, but its dimensions ware not right for me. I wanted it to be thicker, with a strong grip handle.
So based on those plans and to the wood stock I had, I re-design one to my own dimensions.

I had few small pieces of hardwood that looked the right size and that I have been saving in my shop for this reason – to build myself a mallet.

I wanted my mallet to have a variety of wood species build into it, so…:
I used Oak for the left/right head sides, Padouk hardwood core with a 4cm diameter hole at each side filled with small shotgun lead beans which I found inside an old baseball paper weight, Merbau hardwood for the handle (two pieces glued back to back) and Beech wood for the wedges.

To get a darker color out of the hardwoods I finished it with Pure Tung Oil.

At first it was not my intention to make it as heavy and strong, but it came out to be a real Lethal Weapon.
It has a nice thick grip in my hand and is heavy enough to give an effortless strong blow.

Personally I Love it! Don’t know about you.

Thanks for reading/watching
Stelios L.A. Stavrinides

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --





11 comments so far

View Tag84's profile

Tag84

573 posts in 1312 days


#1 posted 06-30-2013 07:43 PM

beautiful design mallet Stelios! i would like to build one now :)

-- -Thomas -

View steliart's profile

steliart

1807 posts in 1344 days


#2 posted 06-30-2013 11:45 PM

Thank you Tag84, can wait to see yours :)

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View NiteWalker's profile

NiteWalker

2710 posts in 1233 days


#3 posted 07-01-2013 12:53 AM

Beautiful!
I have one of these on my “build it eventually” list. ;-)

-- He who dies with the most tools... dies with the emptiest wallet.

View steliart's profile

steliart

1807 posts in 1344 days


#4 posted 07-01-2013 01:23 AM

Thanks NiteWalker ;)

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View ldl's profile

ldl

1135 posts in 1021 days


#5 posted 07-01-2013 02:33 AM

Nice looking Mallet just don’t miss the chisel. haaa Haaa
It’s big enough to handle most any job for sure.

-- Dewayne in Bainbridge, Ga. - - No one can make you mad. Only you decide when you get mad - -

View Nollie's profile

Nollie

146 posts in 1442 days


#6 posted 07-01-2013 03:28 AM

Good looking mallet . I would put it up in a display cabinet and not use it….lol

-- Nollie Bay City , Tx .http://www.leoncustomfurniture.com

View wseand's profile

wseand

2257 posts in 1698 days


#7 posted 07-01-2013 04:49 AM

She’s a real beaut.

-- Bill - "Freedom flies in your heart like an Eagle" Audie Murphy

View steliart's profile

steliart

1807 posts in 1344 days


#8 posted 07-01-2013 10:19 AM

thanks guys

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View Gibernak's profile

Gibernak

122 posts in 502 days


#9 posted 07-01-2013 06:34 PM

It looks great. Nice work and good inspiration

View Rob Drown's profile

Rob Drown

724 posts in 2489 days


#10 posted 07-04-2013 08:37 PM

That’s a real smacker. Very nice! Any idea what the lead weighed?

-- The expectations of life depend upon diligence; the mechanic that would perfect his work must first sharpen his tools. Confucius, 经过艰苦的努力的梦想可以成真

View steliart's profile

steliart

1807 posts in 1344 days


#11 posted 07-04-2013 09:44 PM

Rob Drown
Sorry Rob, don’t have a weighing machine, but the mallet balances just after the end of the handle.

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

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