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Wood Mallet design drawings


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#21 Swarf

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Posted 03 February 2012 - 02:26 PM

"If you can dream it...you can build it" Who said that? Quite an accomplishment !

#22 Brian VanVreede

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Posted 04 February 2012 - 12:10 PM

Here is the progress that I was able to make this morning at the shop..
It looks a little beat up, but there is alot of material that will be removed to create the steeply angled faces.
Theres a write up on my Blog http://buckscountycr....wordpress.com/

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  • mallet7.jpg
  • mallet8.jpg

I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#23 Brian VanVreede

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Posted 05 February 2012 - 04:03 PM

Alright I was able to get some more work done! :D

Also, another write up on todays progress at my blog! http://buckscountycr...he-goal-spline/

Attached Thumbnails

  • mallet9.jpg
  • mallet10.jpg

I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#24 Brian VanVreede

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Posted 07 February 2012 - 05:13 PM

So its time for me to make the steep angled cut on each of the 4 faces. There is no way for me to make this cut in one pass on the table saw so the table saw is out! I don't own the tool that I think is made for this sort of cut and that is a band saw. I think ill make these 4 cuts with a hand saw.
How would you make that cut?

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I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#25 duckkisser

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Posted 07 February 2012 - 05:39 PM

i would think you can make some kind of jig to make the cuts you are talking about. i know its a pain to set up a jig for one use but still after the work you have done so far what is a little more.
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#26 Brian VanVreede

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Posted 11 February 2012 - 04:50 PM

Ya, I went with the hand saw....... the only problem was is that the saw is a 10 year old Buck Brothers saw that couldnt cut butter! I was only able to get one face cut with the time I had today.


Wish I had one of those "Bad Axe Saws"!!!!!

Attached Thumbnails

  • mallet11.jpg
  • mallet12.jpg

I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#27 JerrySats

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Posted 11 February 2012 - 05:30 PM

Looking good so far , can't wait to see the finished mallet .

#28 duckkisser

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Posted 12 February 2012 - 09:15 AM

hey nothing wrong with cutting old fashoned way.....why don't you sharpen up your saw blade?

i would save your cut offs they are cool looking maybe you can make them into something interesting

#29 Brian VanVreede

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Posted 14 February 2012 - 05:30 PM

The Mallet is FINISHED!! Check out my Blog for the final post on this design!


http://buckscountycr....wordpress.com/

Attached Thumbnails

  • mallet13.jpg
  • mallet14.jpg
  • mallet16.jpg
  • mallet15.jpg

I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#30 duckkisser

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Posted 14 February 2012 - 07:47 PM

thats a nasty crack on the handle i would be leary of using it for any realy hiting.

#31 Brian VanVreede

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Posted 14 February 2012 - 08:03 PM

It was filled with west systems epoxy back when it was still a piece of 8/4 stock. I think it should be ok so there is only one way to be sure and that is to use it for the purpose I made it! If it fails and breaks somehow, I will identify the cause and resolve that issue with mallet #2. But hopefully I wont have to make another one out of necessity.
I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#32 Charles Hicks

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Posted 14 February 2012 - 08:56 PM

Your mallet inspired me to make my own :) I want to make one that looks like Mjölnir haha. I think i am going to do the one from the movie Thor given it's a lot more ornate then the comic version.

#33 duckkisser

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Posted 15 February 2012 - 05:30 AM

you might be able to salvage it if it does break drill a hole and have a tool and dye maker make a metal handle or turn a wooden handle for your mallet.

by the by im thinking of making my own mallet on the lathe anyone got any advice? types of wood? quarter sawn better then face grain ect.....

#34 wdwerker

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Posted 15 February 2012 - 07:53 AM

It turned out very nice. I noticed the lower splines ended up getting cut all the way off.
I have had things like that happen on projects, sometimes it is hard to envision how the angle cuts will affect the rest of the details.
I saw the doggie stairs on your Blog. I made a similar set of stairs for the shop and put a 4 ft tall handle on one side. You can carry it around by the handle and you have something to hang on to as you go up.
Steve Duncan
Fine Custom Woodwork since 1978 ---------------------- www.steveduncan.com

#35 Brian VanVreede

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Posted 15 February 2012 - 09:26 AM

Along with loosing the bottom 2 splines I also gained the streaks in the maple that I thought I had hidden.
I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#36 TimWood

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Posted 17 February 2012 - 03:30 AM

I think the typical is 5 degrees slant/angle on the head. Oops...little late on that but the mallet is beautiful. It would be hard to beat that one up!

I'm not right...but I'm happy


#37 duckkisser

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Posted 17 February 2012 - 04:40 AM

i know you said you wanted to hid the streak but i like it i think the next one you should intentonly find wood with more of that to it. reminds me of a wrap around box that i made
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#38 Brian VanVreede

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Posted 17 February 2012 - 04:52 AM

Looks great duck. I like the streaking also, but it wasn't consistent. It only showed up on 2 of the 4 faces and I had it laid out to have the wrap around effect. Isn't it called maple ambrosia?
I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/

#39 duckkisser

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Posted 17 February 2012 - 05:08 AM

hard to tell on yours it could be or it could just be dirty maple. my box is spalted wood ambrosia is different. spalted comes from mold/fungis growing on the boards. ambrosia i believe is from bugs geting in the tree.

just a heads up you can grow you own spalted lumber http://www.finewoodw...e.aspx?id=32484
i dont work with it with the kids much in classroom since the mold thing but i love the way it looks.

#40 Brian VanVreede

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Posted 17 February 2012 - 04:40 PM

Interesting article.
I don't cut corners, I mitre them! Follow my blog @ http://buckscountycr....wordpress.com/





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