Chestnut

Brass Mallet

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I keep seeing those Dema Hammers on instagram and i always want one but when ever i check his etsy it's never listed. So I'm taking things into my own hands. This is my build

I got the brass hex in the mail today. I should have enough to mess this up a couple times before i get it right. My first one won't have the awesome turned finish his does because i don't have a lathe buy my neighbor is a machineist so when the weather gets nice and use northerns finally come out of hibernation I'll ask him if he'll machine me one.

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They were everywhere a few weeks ago. I’ve never used one so I don’t see the fuss but I have been thinking about making one as well. 

Does he stabilise his handles with resin? I saw he did that for a mallet that he turned. 

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9 minutes ago, lewisc said:

They were everywhere a few weeks ago. I’ve never used one so I don’t see the fuss but I have been thinking about making one as well. 

Does he stabilise his handles with resin? I saw he did that for a mallet that he turned. 

I'm pretty sure he does. I was just going to find some exotic or something i have laying around to make the handle from. i don't have a lathe so it's going to be shaped with a rasp and be pretty ugly. Maybe some day i'll get a small lathe for stuff like this.

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Bandsaw out 4 sides of a handle shape, sand, scrape or file the centerline of each side smooth. Then use a roundover bit or a table edge/ thumbnail profile if you've got one. Use a rasp, file or scraper to smooth out the transitions. Sand from there and no lathe needed. 

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3 hours ago, lewisc said:

Does he stabilise his handles with resin? I saw he did that for a mallet that he turned. 

He does. I have a cocobolo handled one from him.

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This is turning out to be a fun quick project. I meant to make a spline/key/miter reinforce jig tonight but this took my attention.

Got a piece cut off, this was probably the most difficult part.

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I squared the end and put bevels on the edge with a bastard file, because a file doesn't really cut that cleanly i used a piece of 120 on my bench to start the clean up. Moved to 180 than 220 than 600 and finished at 800.

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I hit it with some polishing stuff that i use on the strop and it got pretty shiny looking. I know if i had one of those cotton wheels and some compound i could get this mirror smooth in short order. Tapped a hole for a bolt. I'll use the bolt expoied into the handle to help reinforce it just like dema did in his video.

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39 minutes ago, pkinneb said:

He does. I have a cocobolo handled one from him.

What are you finding you use it for?

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2 minutes ago, Brendon_t said:

Dema had some posted yesterday I thought

He has a pre-order up 4-5 week lead time. It was too late by the time i saw that i had the brass bar on the way to my house. It was only $50 for the bar.

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1 hour ago, lewisc said:

What are you finding you use it for?

Well actually I haven’t actually used but it looks really nice lol

 

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53 minutes ago, Chestnut said:

He has a pre-order up 4-5 week lead time. It was too late by the time i saw that i had the brass bar on the way to my house. It was only $50 for the bar.

Where did you order the brass from?

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14 hours ago, wtnhighlander said:

Where did you order the brass from?

Amazon, i got 12" long stock so i could make 5-6 of these depending on how big i wanted to make the heads this one is 2" long.

https://www.amazon.com/gp/product/B000H9G1RK/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

Huh price jummped up a bit, 1-1/4" stock is cheaper and might not be that different in size.

 

15 hours ago, Woodenskye said:

I know brass is a softer metal, but I would have used a different saw.

I did use a different saw i was just doing that to mess with people.

Got a handle Layout.

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Cut on the bandsaw and shaped a bit with a rasp. Then followed with the belt stander. Found out that a hold fast is awesome for keeping that in place.

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Lots and lots of sanding later it's being epoxied up.

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I have no idea what the wood is. A guy gave me a stick and told me it was myrtle i trust him but it looks a bit off to me.

 

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21 hours ago, Chestnut said:

 

https://www.amazon.com/gp/product/B000H9G1RK/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

Huh price jummped up a bit, 1-1/4" stock is cheaper and might not be that different in size.

 

Looks like everything in that link is unavailable on 1.5, 1.25, and 1".

I was definitely thinking of doing one/two as well

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9 minutes ago, Brendon_t said:

Looks like everything in that link is unavailable on 1.5, 1.25, and 1".

I was definitely thinking of doing one/two as well

1-1/8" $35
https://www.amazon.com/dp/B000H9N1I2/ref=biss_dp_t_asn

Only 1 in stock.

1-1/4"

https://www.amazon.com/dp/B000H9N1M8/ref=biss_dp_t_asn

I think the 1-1/2" is on the too big side 1-1/4" i'd like to try see if it balances a bit better. Could also makes the head longer to allow more knuckle clearance.

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This was my first attempt, back in Feb.  If I  make another I will shorten the handle by 1 1/2", might shorten the head too, not sure.  Fun project, I use it all the time for gentle taps on my chisels.  Used curly maple for the handle.

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On 4/14/2018 at 1:08 PM, Chestnut said:

 

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Is there a dowel rod or threaded metal of some sort attaching the handle to the head or just epoxy? 

On 4/14/2018 at 1:08 PM, Chestnut said:

 

 

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9 hours ago, K Cooper said:

Is there a dowel rod or threaded metal of some sort attaching the handle to the head or just epoxy? 

 

Yeah I can't remember what size i used probably 3/8" but possibly 1/2"

I bought some rosewood and bocote, I plan to make another sometime. My neighbor has 3/4s of a machine shop in his garage so I'm going to ask him to turn down the brass on his metal lathe.

Almost every single neighbor around me has a cool hobby. One restores old fiberglass boats, one restores old american cars, another restores old european cars, and a regular boat guy.

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On 5/14/2018 at 7:47 AM, Chestnut said:

Yeah I can't remember what size i used probably 3/8" but possibly 1/2"

I bought some rosewood and bocote, I plan to make another sometime. My neighbor has 3/4s of a machine shop in his garage so I'm going to ask him to turn down the brass on his metal lathe.

Almost every single neighbor around me has a cool hobby. One restores old fiberglass boats, one restores old american cars, another restores old european cars, and a regular boat guy.

Dang I want to live on that street! 

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Just now, bushwacked said:

Dang I want to live on that street! 

There is a house for sale down the street for the low low price of $850k :ph34r::D

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4 minutes ago, Chestnut said:

There is a house for sale down the street for the low low price of $850k :ph34r::D

Hell let me call my realtor right now then :P 

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