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Supporting Our Service Members
We proudly stand with all United States service members in Operation Epic Fury and those deployed around the world. Your sacrifice, courage, and dedication are deeply respected and never forgotten.
  1. Drawing a Curve on the Mallet Head
  2. Cleaned up Glue
  3. Wedging the Mallet Handle to the Head
  4. Checking the Slot Width Fit
  5. Test Fit
  6. Mallet Heads
  7. Cutting Mallet Blanks from Billet
  8. Checking Handle Slot Alignmnet
  9. Shoulder Plane and Mallet Blanks

Test Fit

John Morris

By John Morris

The handles are just dry fit into the slots. To get a great fit I had to sneak up on the handle widths, as not all handle slots in each mallet were the same as the next, because I cut these on the table saw without any jigs, just eyeballing lines is all. So each mallet was a tad different. I had to plane each handle to fit each slot right. I'll have a better assembly process next time, I plan on making many of these and pass them out as gifts and possibly sell them as well.

From the album:

Big Ash Mallet

· 13 images

Photo Information

  • Taken with SONY DSC-HX100V
  • Focal Length 4.8 mm
  • Exposure Time 1/13
  • Aperture f/2.8
  • ISO Speed 100
View all photo EXIF information

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