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Woodworking on a Half-Shoestring #85: Joiners Mallet

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Blog entry by Paul Bucalo posted 11-23-2016 12:03 AM 1034 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 84: Harbor Freight's DrillMaster 2 HP Fixed Base Router Fix Part 85 of Woodworking on a Half-Shoestring series Part 86: Repair Broken Handle on Antique Rolling Pin »

I’ve been wanting a larger mallet for chisel work, but until now didn’t have a large enough piece of hardwood. The head is oak, part of a pallet runner I acquired in the summer. The handle was make from a section of an old, discarded TruValue snow shovel handle; probably ash. I mounted the handle in my lathe and reduced the section that will fit into the 1” hole made in the head. The faces have a 2 degree rake toward the handle. Some subtle work was done on the rest of the handle for a more comfortable grip. Epoxy was used to glue the tight-fitting handle to the head. One coat of Danish oil for the finish.

Update: A day later, I got a chance to find out if the mallet was going to be an asset in the shop. I clamped down a thin scrap of poplar and chopped a square through-mortise the width of a Harbor Freight chisel that was sharp enough to cut you, but not able to shave the hairs off your arm. The mallet worked better than I had hoped for.

I was surprised at what little effort I had to put into each swing. I wasn’t sure the mallet had enough weight for chopping out mortises. Remember, not the sharpest chisel in the lot. ;)

“My kingdom for a tenon!”

“No pain, all gain.” Works well enough for what I can do. Passed! (My first truly useful mallet!)

-- -- Paul @ PMB Creative Works



4 comments so far

View luv2learn's profile

luv2learn

2653 posts in 2112 days


#1 posted 11-23-2016 12:17 AM

Nice combination of scrap materials Paul. I like your re-purposed mallet.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View ralbuck's profile

ralbuck

3622 posts in 2076 days


#2 posted 11-23-2016 01:06 AM

I relly like that you spared no expense in the build!

Most of my projects are made that way too. Fire wood and scraps are my lumber yard!

GREAT usable tool!

-- SAWDUST is THERAPY without a couch! just rjR

View Paul Bucalo's profile

Paul Bucalo

637 posts in 1169 days


#3 posted 11-23-2016 03:47 AM

Thanks, Lee. You know me: waste not, want not. :)

-- -- Paul @ PMB Creative Works

View Paul Bucalo's profile

Paul Bucalo

637 posts in 1169 days


#4 posted 11-23-2016 03:48 AM

Ha! Thanks, rjR. No castout is too good for my projects. :D

-- -- Paul @ PMB Creative Works

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