Reply by FJPetruso

I checked my ole store bought mallets. The larger one that I bought from Rockler has about 4 degree angle faces. When I use it I feel as though I’m turning my wrist a bit forward to keep from hitting off of the lower edge of the face. The smaller one that I bought at Harbor Freight has 5 degree faces. The smaller HF model has a better feel but it’s too light for some jobs. The smaller, lighter one has a shorter handle too. So that may make a difference. When I make my own I’m going to start with about a 7 or 8 degree angle & a straight stick handle for testing. With the tapered, removable style handle I’ll be able to trim the angle down a little at a time until I get the right feel. I may even try knocking the handle out of the Rockler mallet & increase the angle a degree or two at a time & see how it feels first.

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"