Chuck, can I ask a few questions?
1. What's the difference between a dead blow mallet and a carver's mallet and why? What exactly do you use a dead blow mallet for?
The dead blow mallet is a assemble mallet. for driving things like dove tails together. It has a flat face and when cut at the angle it will stick the wood flat.
To make it a dead blow I put a slot in it for steel shot. t=The shot will roll to the top of the slot when you raise the mallet up and than as you strike, it will slam down to the bottom of the slot increasing the force of the mallet.
The carvers mallet is for hitting your chisels. They make them round so you can keep changing the spot where the chisel hits the head to prolong the life of the mallet.
2. Why do you use green wood for the head (or top)? I know turning green wood for the handle is easier, but why the top too?
The wood I used was green when I got it. Being hickory it is very hard when dry. Hard wood is hard to route cut and sand so I went ahead and milled it green. I prolly would not do it again if I didn't have to get an order out.
3. Why do you coat them with epoxy?
The epoxy I use is water proof. If water can't get in than it can't get out so the mallets should be very stable. Also it is very hard which will help make the mallet harder and last longer.
thanks Chuck.