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Trigger's Mallet

This is where we don't want anything but evidence of your finest wood butchering in all its glorious, and photograph laden glory. Bring your finished products or WIP's, we love them all, so long as there's pictures, and plenty of 'em!

Trigger's Mallet

Postby Steve Maskery » 20 Jan 2022, 17:48

I have a nice little rubber mallet. I'm ashamed to say that I can't remember who gave it to me. If it was you, Thank You, I enjoy using it, it's great for assembling small projects.

original mallet.JPG
(252.61 KiB)


There was a small split in the handle when I got it and over the last few years that split has got bigger and bigger. A couple of weeks ago, as I was assembling Stuart's casket, a chunk flew off over to the other side of the workshop. It was a shame, I like that mallet.

damage closeup.JPG
(211.29 KiB)


So I decided to make a new handle. But in separating the head and handle, I discovered thatt he head was also split.

split head.JPG
(216.17 KiB)


Now superglue is excellent on rubber, but I figured that this was perishing anyway, so perhaps I should replace the head, too.

I cadged a piece of ash off Roger (thanks, Roger) and glued two pieces together to form a head blank, which was then morticed and the mortice flared out.

head blank.JPG
(198.72 KiB)


mortice.JPG
(239.18 KiB)


tapered mortice.JPG
(221.75 KiB)


I cut the handle blank on the tablesaw, but all the tenon work was done entirely by hand. Saw and chisel.

paring shoulders.JPG
(257.2 KiB)


I shaped the handle also by hand. Spokeshave and rasp, sandpaper.

shaping handle 1.JPG
(262.1 KiB)


shaping handle 2.JPG
(232.48 KiB)


spokeshaving handle.jpg
(281.77 KiB)


I cut a couple of bog oak wedges and began assembly

the component parts.JPG
(249.41 KiB)


wedges glued in.jpg
(229.59 KiB)


This turned out to be a bit of a mistake. This bog oak gets everywhere, and later on the ash got very grubby very quickly. I should have finished all the ash before touching the bog oak. Next time, eh?

The main problem with using wood for a small mallet head is that it's not very heavy. Certainly it is lighter in feel than the rubber head. So I decided to increase its density by embedding some lead into it.

First of all I had the idea of drilling a cavity and filling it full of lead fishing weights and epoxy. I went to two fishing shops and neither had lead line weights, They were all labelled "non-toxic". I don't know what they are made of, but they certainly don't have the heft of lead. But they did have the larger weights, so I bought one of those, 12oz.

My first approach was to drill a couple of holes in a block, melt the lead and cast it. But I'd only just got going when my gas ran out. I do think that it would have worked quite well. But no gas equals no casting, so I got a big hammer and just beat the living daylights out of it until it would fit. Fun, but hard work, my arm was shaking by the end of it. The two ingots were glued in with epoxy.

shaping lead.JPG
(258.82 KiB)


fitting lead plug.JPG
(240.13 KiB)


Then it was a case of adding a couple of bog oak faces and cleaning up. It was at this stage I realised how beneficial it would have been to seal the ash first.

bog oak faces.JPG
(233.3 KiB)


But it did clean up and I added a couple of leather faces. It's not hide, it was from an old sofa that one of my neighbours was trying to burn in the garden (that's how we get rid of stuff in Kirkby, we set fire to toxic material in the back garden), I think it is the leather equivalent of MDF.

leather faces.JPG
(245.72 KiB)


So now I have a very nicely repaired mallet. New handle, new head, two new wedges.

finished mallet.JPG
(232.06 KiB)


Trigger would be proud.
Last edited by Steve Maskery on 20 Jan 2022, 23:16, edited 3 times in total.
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Re: Trigger's Mallet

Postby kirkpoore1 » 20 Jan 2022, 19:01

Excellent, especially the work-around.

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Re: Trigger's Mallet

Postby Alf » 20 Jan 2022, 19:05

Very nifty. :eusa-clap:
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Re: Trigger's Mallet

Postby Malc2098 » 20 Jan 2022, 19:23

Proper job!
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Re: Trigger's Mallet

Postby Steve Maskery » 20 Jan 2022, 19:35

And just in case there are any Martian's viewing...
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Re: Trigger's Mallet

Postby Andyp » 20 Jan 2022, 19:48

high praise indeed from Malc.

I think it is nice. :)




Very nice.
I do not think therefore I do not am.

cheers
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Re: Trigger's Mallet

Postby MY63 » 21 Jan 2022, 08:24

Steve I am sure I can find some offcuts of veg tanned leather for your mallet faces if you would like some it is around 2.2mm thick.
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Re: Trigger's Mallet

Postby Steve Maskery » 21 Jan 2022, 09:16

That is very kind of you Michael. I'll PM you my address.
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Re: Trigger's Mallet

Postby MY63 » 21 Jan 2022, 10:53

Steve Maskery wrote:That is very kind of you Michael. I'll PM you my address.
S

I have a piece 20cm x 8cm x 2.2mm is that big enough for both ends.
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Re: Trigger's Mallet

Postby Steve Maskery » 21 Jan 2022, 10:55

Plenty, yes, thank you.
S
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Re: Trigger's Mallet

Postby AJB Temple » 21 Jan 2022, 11:38

Very nice. You could go into production on those.
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Re: Trigger's Mallet

Postby Cabinetman » 21 Jan 2022, 11:53

Very nice, I wondered how you would get over the fact that it would probably mark what you were hitting, love the shape of the handle just hope it’s not a little thin just below the head, time will tell! Ian
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Re: Trigger's Mallet

Postby Stuart » 21 Jan 2022, 12:49

That’s nice Steve. I’ve really got to get round to remaking mine, it’s rather battered!
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Re: Trigger's Mallet

Postby Alf » 21 Jan 2022, 12:55

AJB Temple wrote:Very nice. You could go into production on those.

If you stick with the faux leather, Steve, you can market them as Vegan Mallets and charge a premium.

Alternatively go with the real leather, use hide glue, and MeatEaterz Mallets™ are born.
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Re: Trigger's Mallet

Postby Steve Maskery » 22 Jan 2022, 10:05

Alf- LOL!

Look what I've got, the photo does not do it justice.

leather.jpg
(320.97 KiB)


It is beautiful and, even though I know nothing at all about tanning leather, I suspect that this is a high-quality, hand-crafted product.

Thank you very much indeed, Michael.
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Re: Trigger's Mallet

Postby MY63 » 22 Jan 2022, 19:28

You are welcome Steve pleased I could help out, It arrived quickly I only posted it at around 11.30 am yesterday. The leather is veg tanned much easier to work with than wood.
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Re: Trigger's Mallet

Postby Woodster » 23 Jan 2022, 13:28

Nice job on the mallet Steve.

I don’t really need one as I’ve got a couple of nice hide mallets. I’ve not thought of using leather faces before though so as I have some nice thick stuff somewhere I’ve added a leather faced mallet to my project list.
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Re: Trigger's Mallet

Postby Steve Maskery » 23 Jan 2022, 13:33

It's a tool, what's "need" got to do with it?
:)
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Re: Trigger's Mallet

Postby Steve Maskery » 23 Jan 2022, 21:36

And the YT:



Enjoy!
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