[Original thread and discussion are at http://familywoodworking.org/forums/...ad.php?t=22621 - VM]
First off I start with some good green Hickory
Than cut out the head mine is 2.75 wide by 3.75 tall by 5 inches
It is hard to see in the pic but each end is cut at a 5drege angle.
Now that the head is cut to size it's time to drill it. I am using a 1.25 bit for this.
Now to bevel the top. i whipped up this quick sled for the job of putting a 5 degree bevel on the top of the head.
A quick trip around the head with a .25 inch round over bit.
Now it's time to set the head aside in some DNA for a spell.
You can see one laying on it's side with a .75 by .5 slot cut into it. I did that with a plunge router. That slot will be 1/2 to 3/4 filled with steel shot. To make a dead blow mallet.