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  1. Here we are a week into October already. Beautiful day here is southern PA. The leaves are beginning to change. Our turners have been quite busy this week, so lets get started. Our Patriot Turners- A while back, @DRAGON1 asked if one of our members could turn a large coffee mug. @Gerald came through with TWO mugs- More in Dragon1's post- Speaking of @Gerald, he is experimenting with some new inks to add color to his turning- Gerald tells us more about this piece in his post- Gerald also sho
  2. I had a little fun in the shop this morning. Soon I'll be firing up some chairs to build, and right now I am kind of jigging up and tooling up for this big project. Besides the jigs my son and I have been working on, today I got in the shop and made one complete mallet, and I have a couple more in the wings that need to be made as well. Before I took these images I had already made my layout lines and cut the mallet handle slots on my table saw. I simply set my table saw t-slot miter to 4 degrees and cut the slots in from one side then I set it at 4 degrees the other way and cut the other
  3. Hope this Wednesday finds everyone healthy and still sane. Our Patriot Turners- @Ron Altier is holding up well under the lockdown. He finished up a sweet little ornament that has a whole bunch of glue-ups! Here's his post- @Gerald had a new comment one of his beautiful bowls in our gallery. Check out his post and read about the tree species- What’s Coming Up- It has been tough coming up with shows and symposiums. Last thing I read was that the Mid-Atlantic Woodturners are unsure if they will be able to have
  4. Haven't had a chance to view the entire video, but it's a neat take on a carving mallet.
  5. John Morris

    Ash Mallet is Done!

    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.
  6. I decided I'd replace my old wooden mallet.................because I can't find it. I haven't looked too hard, but I have a feeling someone borrowed it some time ago. Anyway I used some red Oak, beetle kill pine (handle) and Paduke. The handle was going to be about two inches longer, then one inch and finally where it is........because that is what was left after I made a misque. Would you put some material on the striking surface, hard rubber/plastic or something? I only use it with woods or softer things.
  7. Been a crazy week but I did get a little time in the shop. Our Patriot turners have been busy, too! Our Patriot Turners- @Ron Altier posted another of his fantastic ornaments! That SpectraPly really creates some interesting patterns You can read more about this turning in Ron's post at- Ron asked us if anyone experienced allergic reactions to the colored plywood similar to what he uses for his ornaments. He received lots of comments. Please check his post and see if you can add anything to the discussion- Ron is our big winner, this
  8. Just think, in less than 2 weeks, we will enter Daylight Saving Time- for those who live in states that utilize this archaic standard. This sees to sum it up- Our Patriot Turners- Member @Thad posted a new project of some handles he was turning. Thad also asked our turners about making ferrules. The handles turned out fantastic! Check out the post here- @Ron Altier Started a discussion concerning using gloves while turning and if that practice was safe. Lots of thoughts and discussion followed- Ron also pos
  9. From over working the Single Brain Cell Sketch-up. It was on over load trying to figure out a tool box build. Had a blank of spalted....something or other Well, this is the leftovers. It was 22" long, cut it in half. Drug the old Craftsman T rail lathe up off the storage crates, and fastened it down to my bench. Only place I have down there to run a lathe. Kept looking through stuff, trying to find the "pattern' i wanted. Got the blank mounted on the lathe, and turned round. Chippy stuff, no shavings. Got a start at just winging it from memory, and looked over and found the pattern
  10. My haul from last weekend, this is just a partial inventory of what I brought home. I only had to clean and clear a widows garage and out building area. She was a complete sweetheart, I loved hearing the stories of her husband while my son and I worked. The above is just a fraction of what was bestowed upon me. How I came into this, her neighbors are lifelong family friends of ours, and long time friends of hers. She
  11. I have this old brass Gray Canada mallet that belonged to a beloved older machinist we worked with. It has been given to a coworker for remembrance. it has no handle , I cannot find any illustration of it anywhere and hope somebody can help me to reproduce a handle for it and pit it back in service. Does anyone know what the handle should look like? image:3618 image:3619 image:3620 image:3621
  12. John Morris

    Hand Tools

    This image is an open sourced image uploaded to this community for re-use within our community graphics.

    © Attribution 4.0 International (CC BY 4.0)

  13. I really enjoy making these mallets. Something about it that is very relaxing. I'll just have to find some owners for em since I can only use one at a time! Here are my first two. Just doing a hit and run topic from my shop. Don't you just love how you can start topics and upload images all from a smart phone in our community. The software we are using is most excellent.
  14. 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.
  15. John Morris

    Just a Fun Image

    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.
  16. John Morris

    The Arc

    From the album: Big Ash Mallet

    The arc.
  17. 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.
  18. John Morris

    Cleaned up Glue

    From the album: Big Ash Mallet

    Cleaned up the glue a tad
  19. 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.
  20. 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.
  21. John Morris

    Test Fit

    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.
  22. John Morris

    Mallet Heads

    From the album: Big Ash Mallet

    Blanks ready to be glued up
  23. From the album: Big Ash Mallet

    I cut my lay out lines to produce the mallet blank halves. The key angle here is 5 degrees on the face. This allows your mallet to be used flush on a bench without your knuckles hitting the bench top but at the same time to have a sweet spot at the arc of your swing or tapping.
  24. From the album: Big Ash Mallet

    Before I took these images I had already made my layout lines and cut the mallet handle slots on my table saw. I simply set my table saw t-slot miter to 4 degrees and cut the slots in from one side then I set it at 4 degrees the other way and cut the other slot in the other side, then I hogged it out with several passes over the table saw blade. My 12" blades have 1/4" wide teeth so it didn't take long to hog the slots out. I laid out 3 mallets and gang sawed them.
  25. From the album: Big Ash Mallet

    I cleaned up the slots with shoulder plane, the slots were heavily kerfed so I used the shoulder plane to knock the kerfs down, not all the way, but just enough to clean it up.
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