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First Mallet

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Project by Don Broussard posted 11-09-2013 at 11:37 PM 1211 views 8 times favorited 16 comments Add to Favorites Watch

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!





16 comments so far

View terryR's profile

terryR

3068 posts in 945 days


#1 posted 11-09-2013 at 11:59 PM

Wow, Don, that’s sorta pretty for PT wood! Looks like a great smashing tool, for a terrific price. :)

-- tr ...see one, do one, teach one...

View Greg..the Cajun  Box Sculptor's profile

Greg..the Cajun Box Sculptor

5034 posts in 1946 days


#2 posted 11-10-2013 at 12:54 AM

I knew the minute I saw it that it was a right handed functional dead blow mallet.

-- If retiring is having the time to be able to do what you enjoy then I have always been retired.

View Rick's profile

Rick

6454 posts in 1670 days


#3 posted 11-10-2013 at 05:52 AM

Very Nice Project Indeed! Thanks For Posting.

Actually Greg I’m Pretty Sure It’s Left Handed. For Guys Like me …LOL…

Rick

-- COMMON SENSE Is Like Deodorant. The People Who need It Most, Never Use It.

View Rob Drown's profile

Rob Drown

724 posts in 2470 days


#4 posted 11-10-2013 at 06:03 AM

Very cool mallet. Looks good. Bet it packs a whallop.

-- 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 Belg1960's profile

Belg1960

794 posts in 1702 days


#5 posted 11-10-2013 at 01:13 PM

Don, this looks like it will be a very useful addition to the workshop. One suggestion would be to round the edges of the head ever so slightly as an angled blow would surely leave a distinct mark with a sharp edge. I really like the spline idea for the handle.

-- ***Pat*** Rookie woodworker looking for an education!!!

View Airframer's profile

Airframer

2416 posts in 590 days


#6 posted 11-10-2013 at 03:49 PM

Nice looking beater you have there. Nice job!

-- Eric - http://theidiotgaloot.com

View helluvawreck's profile

helluvawreck

15661 posts in 1504 days


#7 posted 11-10-2013 at 03:50 PM

This will definitely be a nice asset to your shop. Congratulations.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View Dave's profile

Dave

11160 posts in 1477 days


#8 posted 11-10-2013 at 05:07 PM

Now that should get the job done.

-- Superdav "No matter where you go - there you are." http://chiselandforge.com

View john2005's profile

john2005

924 posts in 815 days


#9 posted 11-10-2013 at 05:26 PM

Looks like a good tool. I like how the wedges all but disappears. Kindof a neat trick

-- In theory there is no difference between theory and practice. In practice there is.

View Don Broussard's profile

Don Broussard

1951 posts in 889 days


#10 posted 11-10-2013 at 07:51 PM

Thanks for all the kind comments! I was like a hunter on the prowl this morning in the shop, just looking for something to whack. No dovetails, no box joints or M&T’s waiting their turn, so I ended up just whacking a lonely piece of pine. Very solid and pleasing!

@terryR—I cut the head out of the stock piece to have the knot in the middle of the head. I like it too.

@Greg—The hammer is actually ambidextrous by design, but it does work better in MY right hand.

@Belg—I did end up softening up all the edges, per your suggestion. A small detail that made a big difference. That suggestion sounded like one based on experience . . .

@John—The almost matching grain between the handle and the wedge was not by design. but it is a neat disappearing act.

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

View Belg1960's profile

Belg1960

794 posts in 1702 days


#11 posted 11-11-2013 at 12:23 PM

Don, it came from reading enough info from others. Glad it made sense to you. Pat

-- ***Pat*** Rookie woodworker looking for an education!!!

View Bearpaw's profile

Bearpaw

208 posts in 2357 days


#12 posted 11-11-2013 at 04:09 PM

Just in time for the movie – Thor. Looks great.

-- "When we build, let us think we build forever." John Ruskin

View Don Broussard's profile

Don Broussard

1951 posts in 889 days


#13 posted 11-11-2013 at 04:58 PM

@Bearpaw—I haven’t named mine yet, but I understand that a Viking name is “required”.

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

View Dave's profile

Dave

11160 posts in 1477 days


#14 posted 11-13-2013 at 01:09 PM

Don I named mine SILK. It stands for son in law killer ;)

-- Superdav "No matter where you go - there you are." http://chiselandforge.com

View Don Broussard's profile

Don Broussard

1951 posts in 889 days


#15 posted 11-14-2013 at 01:25 AM

@Dave—That’s funny, but it doesn’t sound “Viking” enough.

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

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