|Project by Don Broussard||posted 11-09-2013 11:37 PM||1450 views||8 times favorited||16 comments|
Nothing fancy. Just a deadblow wooden mallet out of pressure-treated wood. Not the best wood, but I had it on hand and I wanted the mallet to be softer than my project pieces. And yes, I used a dust mask during milling and sanding operations. I used fishing weights in the chambers for the deadblow. The holes are 1-⅜” diameter.
The head’s sides are at 5 degrees and the top of the head was rounded on a disc sander by eye. Head is 3” tall x 5” wide x 3” thick. Assembled length is 13”. Total weight is about 20 oz.
I shaped the handle with rasps—that was actually pretty enjoyable. Fits my hand well.
EDIT: I forgot to mention that there is a wedge in the top of the handle to keep the head tight onto the handle—I added a picture to show that. It’s hard to see since the grain of the wedge almost matches the grain in the handle. I plan to do a little more shaping on the handle too—more rasping is in my future!
-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!