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Showing results for tags 'ash mallet'.
Found 10 results
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From the album: Big Ash Mallet
All the edges of the mallet were chamfered with my block plane and the handle of the mallet of was shaped using my draw knife and a card scraper.- 3 comments
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- ash mallet
- block plane
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From the album: Big Ash Mallet
Here is a fun picture showing the hand tools I used to help make this mallet, it took a combination of my table saw to make the slots, the shoulder plane to clean up the slots, the miter saw to cut the blanks at 5 degrees, and my hand tools to shape and make it interesting. -
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From the album: Big Ash Mallet
The finished mallet at the right, and my two roughs waiting in the wings on the left. I put a very heavy coat of Watco Danish Oil on and wiped off.-
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- watco danish oil
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From the album: Big Ash Mallet
The arc. -
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From the album: Big Ash Mallet
I used my bow arc to make the arc on the top of the mallet. Was an arc needed? No, but the mallet looks better with some shape to it. -
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From the album: Big Ash Mallet
Cleaned up the glue a tad -
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From the album: Big Ash Mallet
Lots of glue in around the handle, and on the wedges, I wanted the entire slot filled with either wood or glue, securing it for life. I tapped the outer wedges in just a tad, and I drove home the two center wedges pretty hard. Keep in mind, if you make a mallet, the wedges must be tapped in perpendicular to the grain to avoid splitting the wood. -
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From the album: Big Ash Mallet
A dry fit looking at the top of the mallet, the slot is tapered, so the bottom is tight and snug, the top is flared out leaving room for the wedges to secure the mallet. When I do these again I'll cut the slots so there is not much of a flare out at the top, it's really not needed. I think a 2 degree slot flare would suffice next time instead of the 4 degree. -
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From the album: Big Ash Mallet
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.
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