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Thread: Making a Wooden Mallet

  1. #1
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    Making a Wooden Mallet

    Now that I have two holdfasts, I need a decent wooden mallet, I found >> THIS << little tidbit on Lee Valley

    Using the "Sandwich" method, suer seems a lot easier than trying to make that tapered mortise in a hard piece of Beech

    I'm looking at the traditional "English" style of mallet, like this.....



    How does one make the tapered mortice, just out of curiosity
    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
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  2. #2
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    Might look cool if you use a different type/color of wood for the center or "meat" of the sanwich.

    Just out of curiosity...why not just turn a BIG heavy round mallet? What, are you sliding back up the slope towards more flatwork?
    A man is rich in proportion to the number of things he can afford to let alone. -Henry David Thoreau
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  3. #3
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    I don't know but...

    My guess is to place a spacer under the block of wood you are using as the head, one side at a time so that the block is presented to the mortiser at an angle.
    Attached Thumbnails Attached Thumbnails Beveled Mortise.JPG  
    Last edited by Frank Townend; 04-22-2009 at 02:54 PM.



  4. #4
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    Not turned?

  5. #5
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    Quote Originally Posted by Frank Fusco View Post
    Not turned?
    It's a mallet, Frank - not a club!
    Jim D.
    Adapt, Improvise, Overcome!

  6. #6
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    Quote Originally Posted by Stuart Ablett View Post
    ...How does one make the tapered mortice, just out of curiosity
    With a mallet and a chisel. I'd probably make a guide block for the chisel to help keep the mortise's ends straight.

    Somewhere - don't recall where - I saw a mallet that was made in one piece by gluing up quarter inch thick alternating pieces of maple and cherry, then shaping with a rasp. Made a pretty nice looking mallet.
    Jim D.
    Adapt, Improvise, Overcome!

  7. #7
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    Aw come on, turning one is just so easy

    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
    William Arthur Ward

  8. #8
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    Like Jim said. Drill & chisel the mortise straight first and then chisel the angle using a reference block to make sure your chisel is at the right angle. I have never done it in hard beech. At least that is how I did it while making wedged mortise and tenon. Looking foreward to seeing how you make out.
    Last edited by Bill Satko; 04-22-2009 at 09:19 PM.

  9. #9
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    Quote Originally Posted by Jim DeLaney View Post
    It's a mallet, Frank - not a club!
    This is what I mean by carvers mallet. Bonkers are clubs.
    Attached Thumbnails Attached Thumbnails mallet.jpg  

  10. #10
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    Just drill the holes at an angle, slightly shy of the ends of the mortise and then clamp the mallet head AND a spacer the same thickness as the head in your bench vice with the spacer level and the mallet head tilted to the appropriate angle. lay the chisle flat on the spacer (as your guide) and pare the mortice to the proper dimension & shape.

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