Early Access Video: Build a Much Better Mallet
Added 2019-12-14 01:08:08 +0000 UTCFriends;
You know what tool doesn't get enough attention? The humble wooden mallet. It can be just two piece of wood, but there are hundreds of variations in size and shape. I should know; I own at least a dozen of them.
But sometimes, I find something special. A few months ago, I came across this traditional joiner's mallet and I knew right away that it was unique. After months of measuring this mallet and revers-engineering it's construction, I'm ready to show everyone how to make this wonderful tool.
As always, the plans I mention are free to Patrons and they'll be ready next week.
Hope everyone has a great weekend!
--Rex
Comments
Thanks! Looking forward to being in way over my head!
Natasha Stuver
2019-12-22 20:46:18 +0000 UTCThe curves do not matter. They are not consistent on the original and I just eye-balled them. A stop cut of 3/16 is about right.
Rex Krueger
2019-12-22 12:43:50 +0000 UTCSo, does the radius of the big curves on the head matter? If so, what might that radius be? Or, how deep was the stop cut you made to help cut those curves?
Natasha Stuver
2019-12-21 23:32:15 +0000 UTCI was pretty bummed. But I have more osage, so I'll make one yet!
Rex Krueger
2019-12-19 11:37:34 +0000 UTCAgreed!
Rex Krueger
2019-12-19 11:37:10 +0000 UTCOkay $5.00 was the cost, just saw that, worth every penny and much more.
Clayton Hartig
2019-12-18 20:46:13 +0000 UTCWhat a fantastic find and a great build. The story behind it and your skills of talk took me to that place you found it. Oh, by the way, I assume he did take $3.00 for it? Lastly, what a let down on the Osage Orange, that was the perfect first selection and an incredible species it is. It turned out great none the less and as always another fine production as usual.
Clayton Hartig
2019-12-18 20:41:24 +0000 UTCDo me a favor and just scan the text of the post again!
Rex Krueger
2019-12-17 11:24:37 +0000 UTCRex, were you planing to make some plans for this mallet yet? I think this video is good enough but was just wondering. Thanks! Larry
Larry
2019-12-17 04:16:53 +0000 UTCAh, . . . ooookay . . . if you insist.
William Allen
2019-12-17 00:16:45 +0000 UTCMan, if you finish that chromatic tongue drum, you MUST make a video of it. I DEMAND it!
Rex Krueger
2019-12-16 23:57:17 +0000 UTCYou mean the Three-Tool Mallet? It's still a fine tool. It's just heavy and a bit rough. I'll still use it for a lot of stuff, but this one is more refined and better for delicate work.
Rex Krueger
2019-12-16 23:56:29 +0000 UTCI was away last week taking advantage of an opportunity to study with a great musician. It was a great experience and has really re-invigorated my music. Which is why I haven’t responded until now. When I saw this hammer I was immediately struck by the same mastery as I see in music. It also makes me want to rush out to the woodshed and build it right now! Music fills my soul with happiness and woodworking calms me down and fills me with peace. I’m currently building a tongue drum, chromatic. Why not combine music and woodworking.? I wonder if I need this mallet to make the tongue drum?
William Allen
2019-12-16 18:10:04 +0000 UTCSo, here's my dumb question: what about the mallet you made at the beginning of this adventure?
John Laudun
2019-12-16 15:47:21 +0000 UTCLive oak is amazing stuff: the fibers of the wood are incredibly intertwined. (Splitting it is a pain, but here that's a plus.)
John Laudun
2019-12-16 15:46:56 +0000 UTCGood luck!
Rex Krueger
2019-12-16 11:28:44 +0000 UTCI think Live Oak would be PERFECT. I often wish I had brought some with me when I moved out of FL.
Rex Krueger
2019-12-16 11:28:19 +0000 UTCSo, I think that with the wedge that way, PLUS the other end slitted and wedged, you just get huge hold. The old one hasn't moved in a century or more. Also, if you made the wedge in the other direction, you wouldn't be able to get it in, since the wedge is smaller than the handle.
Rex Krueger
2019-12-16 11:27:25 +0000 UTCThis really makes me want to make some mallets out of some cherry firewood! Question, what advantage does the vintage mallet have with that wedge that way? Is the big advantage of that mallet the curves and handle detail? Would cutting the wedge the other way cause any difference?
David Bumpus
2019-12-16 01:27:18 +0000 UTCGeez I’d love to buy that mallet you just made. Great video. I’m gonna try to make it. Do you think Florida Live Oak would make a decent mallet head? Love your videos!
Larry
2019-12-16 01:25:33 +0000 UTCAnother great video with valuable tips! We will be moving into our new home I'm building the roman bench and mallet! Thank you for the inspiration!!! Happy Holidays : )
Mark Fannin
2019-12-15 22:23:09 +0000 UTCAnd you can use a penny to lay out that little curve!!
Rex Krueger
2019-12-15 16:51:42 +0000 UTCYou may not be thanking me after the tenth time you have to sharpen your plane. This stuff beats the heck out of plane irons. :)
Bill Smithem
2019-12-15 14:18:01 +0000 UTCI agree. Having used a piece of wood when nothing else was at hand, wood is a lot more like a dead-blow hammer. The rubber mallet bounces quite a bit.
Bill Smithem
2019-12-15 14:13:36 +0000 UTCOnce again you bring us a project that is achievable with a little effort. The subscrition is worth every penny..
Gary Meechan
2019-12-15 13:45:58 +0000 UTCI think that you'll really like the added weight and reduced rebound of the wooden mallet. Used with wooden-handled chisels, they're really magic. Total transfer of force with none wasted.
Rex Krueger
2019-12-15 13:33:22 +0000 UTCI keep hearing about Persimmon! It really sounds like I need to locate some. And yes, make the Sellers mallet first. I did and I taught me how to make mallets. Then I had the skills to make this one.
Rex Krueger
2019-12-15 13:32:03 +0000 UTCIt is kind of crazy how well the notch-vise works. I still use mine from time to time even though I've build a pretty good vise. Also, a plank on horses is a lot like a Japanese bench, so you can can always tell people that you're doing that.
Rex Krueger
2019-12-15 13:30:52 +0000 UTCThank you very much! The detective work was the best and most fin part!
Rex Krueger
2019-12-15 13:29:28 +0000 UTCYou know what Rex? I loved this video man. I came into the video thinking "I've got a couple good mallets, no need to build another one," and I came out of it pumped to go make a new one! I really appreciate the detective work in the beginning of the video. Like how was it constructed, and what are the features, and ooh this part is nice.
Nic Beurskens
2019-12-15 02:59:48 +0000 UTCBTW - I'm currently using a solid core door ($10 off our local Facebook sale page) on sawhorses for a bench. I cut it to 24 inches wide, and was using clamps to hold workpieces on it. Then I re-watched the $30 workbench series. I grabbed my circular saw, and cut a notch in the front edge, made a wedge, and it works great! I showed my son-in-law, and at first he thought I'd ruined my benchtop, but then he saw how it worked. Can't wait til I show him the crochet! :-)
Howard Tuckey
2019-12-14 15:27:51 +0000 UTCIt was my fault when I was putting in the stop cut for the cheek I went a little to deep in one spot, I knew it before I put it together, stubbornness made me say it'll work- famis last words
The Poor Man
2019-12-14 15:21:39 +0000 UTCThanks, Bill! I was just about to ask if persimmon would be a good wood to use for this! I have a 6 foot length of persimmon ( an unproductive tree that I cut from the edge of my garden a couple of years ago) and I was planning to make a Sellers mallet from it. Maybe I do that first, and then this one! Lessee - the Roman workbench, the spokeshave, the vice for the bench, then the mallets. But when do I make the rest of the things I want to make? I guess it's a good thing I'm an old retired guy! :-)
Howard Tuckey
2019-12-14 15:20:17 +0000 UTCI was going to make a Paul Sellers mallet. Now I'm gonna have to turn one of those hunks of persimmon firewood I rescued from my step-son's wood pile into that mallet. I've been using a 16 oz rubber mallet I think I paid $3 for twenty years or so ago. The rubber mallet works just fine for chisel work, but I've been thinking I need to make a wooden one for a couple of years now. For anyone that doesn't know persimmon, it's what wooden golf club heads are made from. Hard stuff. Destroys sharpened edges. Miserable to plane. The one billet I've made from the several pieces of firewood I have took hours with hand tools. Perfect for a mallet that'll last 100 years.
Bill Smithem
2019-12-14 14:28:22 +0000 UTCThe Sellers mallet is good enough for two, especially since it takes a bit of trial and error to get right. I won't even show you the mortise in mine. There's an ugly gap at the bottom.
Rex Krueger
2019-12-14 12:57:52 +0000 UTCI'm delighted you think so!
Rex Krueger
2019-12-14 12:55:12 +0000 UTCRedgum?!? I've never even even heard of that species before. Please let us see the finished product.
Rex Krueger
2019-12-14 12:54:57 +0000 UTCOh, I paid the $5. That guy wasn't dumb.
Rex Krueger
2019-12-14 12:53:54 +0000 UTCI hope your osage works out better than mine did! I'm still a bit disappointed about that.
Rex Krueger
2019-12-14 12:53:32 +0000 UTCIt does swing like a charm! I hope you build it! (Sorry the other one let go on you.)
Rex Krueger
2019-12-14 12:52:51 +0000 UTCI made two of the Sellers mallet...now it is time to upgrade. Thanks Rex.
Rick Prosser
2019-12-14 04:19:23 +0000 UTCFantastic video. This contains everything I love about your channel.
Tom Weinstein
2019-12-14 03:48:56 +0000 UTCI have a lump of nice Redgum that I've been staring at for ages thinking "mallet?" I think this might be the one for it!
Jason Brooks
2019-12-14 03:11:56 +0000 UTC3 bucks, what a steal.. You rock sir.
Heartland Makes & Outdoors
2019-12-14 02:58:01 +0000 UTCMy goodness my friend How awesome is that, I have a piece of Osage orange, I have been planning on making another mallet. This one sir, is the bomb, I cant wait to get it made and in my hands sir. I will check out your plans for this one sir. Thank you so so much for sharing this with us, because, like you, I love it. I agree probably the coolest wooden mallet I have seen. Thanks again sir and have a blessed weekend. Dale
Heartland Makes & Outdoors
2019-12-14 02:55:11 +0000 UTCThat's not a Cadillac that's a Benz. And I've been thinking about the Sellers mallet, or remaking the three tool mallet. I made the three tool mallet about a year ago, but I totally messed up the tenon and one day while using it the head flew off because the tenon failed and let me tell you a huge heavy piece of wood falling out of the sky at your face because your dumb self looked up is a scary feeling. When you first picked up the old mallet and showed it to the camera my very first thought was wow that looks aerodynamic I bet it swings like a charm. I'm looking forward to these plans, I think I may try to build this one. Great video
The Poor Man
2019-12-14 01:37:12 +0000 UTC
