Making a Weighted Carving Mallet

[T.J. Mahaffey]

So far in my ww'ing career, I've turned a few file handles and three mallets. The second, a small diamater version, I did for a fellow galoot I met on the Old Tools list. He was very kind to send me some saw nuts for me to try as a replacement for one I broke. Long story short, I made this mallet for him as a thank you gift. Here's the process, if there's anyone else as green at this as I am. Maybe someone will find something in this useful or aid in their own first attempt.

First pic, mallet clamped in the vise. I actually had the mallet done and finished with some wipe-on poly for at least three weeks before getting to this step. Never having tried to weight a mallet, I was afraid I would screw it up.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet1.jpg

Next pic, a 1/2" forstner bit in the cordless drill. Makes a nice, flat hole.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet2.jpg

As you can see, I drilled it nearly the whole length of the bit. This was so the weight would be more centered in the vertical length of the mallet head instead of the very top. It seemed to me that this would make it feel more balanced in the hand.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet3.jpg

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet4.jpg

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet5.jpg

[T.J. Mahaffey]

The only welding stuff I have is a small MAPP gas torch setup. Up to this point, melting and bending is all I've needed to do, so it works well enough for me. (For the record, I tried just plain propane, but it doesn't get hot enough to melt the lead. Or I wasn't patient enough.)

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet6.jpg

My good buddy, known as woodchuckchuck over at WoodNet, donated a handful of sacrificial lead fishing sinkers for the cause and loaned me his excellent iron ladel, found at a yard sale on our past rust hunts. (He'll be lucky to get the ladel back. I can't wait to get one of my own. Very handy.)

You welders will notice my flame is all out of whack: no oxygen. My oxygen tank ran out as after my first test flame. D'oh! So, I had to go with gas-only. The heat isn't as intense, but it still works, however a bit more slowly.

Notice my use of GLOVES. I don't recommend doing this without some. *ahem*
I happen to benefit from some specialized equipment: my wife's a full time firefighter, so the gloves I have are so good you could practically just use your hand over the flame. :biggrin:

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet7.jpg

Here's the lead all nice and poured in the mallet head. Sweet! I haven't screwed it up yet!

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet8.jpg

Next, I turned slightly oversized plug and sanded a slight bevel on the end by hand. I didn't want the bevel to be too sharp because it would then act as a wedge and possibly split the mallet in half. Just needed a slight angle. I used 2-ton epoxy to glue it in and clamped it as the next picture shows.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet9.jpg

[T.J. Mahaffey]

Next, I cut off the excess with the band saw. Naturally, you could do it just as well with a hand saw instead.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet10.jpg

Then, I used my belt sander to smooth it off. After that, you couldn't tell there was a plug, if you just closed your eyes and rubbed it with your thumb. So far, so good!

And, finally, some additional poly.

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet12.jpg

http://workshop.tjmahaffey.com/workshop/img/tmp/weighted_mallet13.jpg

I'm very happy with how it turned out and I'm glad I swallowed my fear and jumped in to this project. It has given me a bit more confidence.

My advice to others: Don't be afraid! Just do it, dang it! You can't get better if you just sit there worrying about screwing it up and never even start!

[Don Baer]

Good job TJ. I am sure that your buddy will love it. Ya coulda posted that one in the turners forum also...

[Mark Stutz]

That looks great T.J. Have you ever used a weighted mallet? How does it compare to the larger non-weighted version? Are these strictly for carving?

[Mike Henderson]

What does the mallet weigh now, with the lead added?

And what wood is the mallet made of?

Mike

[Dave Anderson NH]

Nicely done TJ. To my way of thinking, anyone who has access to a lathe owes it to themselves to make thier own mallet whether it's weighted or not. Nothing fits the hand quite so well as something you designed yourself, for yourself, and to your own personal taste. The wood is so cheap for so small a project that if your first attempt doesn't feel right, you just make yourself another until you have one you like. It's easy to keep costs down by gluing up a couple of pieces of 6/4 stock to your needed size.

So TJ, what made you decide not to bias the weight toward the top of the head and instead go for a more neutral balance?

[T.J. Mahaffey]

That looks great T.J. Have you ever used a weighted mallet?
Not until now, no.


How does it compare to the larger non-weighted version?
Well, from my one-mallet experience, I'd say the benefit is having more control over a smaller head, but not having to sacrifice force provided by mass. Meaning, with the lead, the smaller head can still provide the same force in small taps as a larger unwieldy head. But, remember, I know zilch about such things. I'm a newbie here. This is just my impression/theory.
I suspect many others on this forum would know far, far more than I on this subject.


Are these strictly for carving?
I'd say no, definitely not. I have made two mallets for myself. A large, non-weighted version in walnut (turned) and a square headed one from maple using lamination. I rarely use the square maple one. I like the feel of the turned one. However, I call the turned ones "carving mallets" because that's what I understand they are typically used for.

[T.J. Mahaffey]

What does the mallet weigh now, with the lead added?
I never weighed it, sorry. :(
but I can tell you I used two large sinkers to fill the head. I'd say the weight difference is maybe 3/4 lbs. (?)



And what wood is the mallet made of?

Mike
Walnut.

[Jim Becker]

Very nice, TJ. I'm wondering if this is something that could be nicely handled prior to turning by using a split blank with a cavity that could be filled with "something heavy", glued up and then turned, eliminating the need to drill in after the fact, etc. Has anyone done it that way?

[T.J. Mahaffey]

Nicely done TJ. To my way of thinking, anyone who has access to a lathe owes it to themselves to make thier own mallet whether it's weighted or not.
I couldn't agree more. No offense meant to anyone here, but I think anyone who actually goes out and spends good money for one is bonkers. ;)

The benefits of making your own:

1. The swell of satisfaction that comes from making and, in turn, using a tool you made with your own hands. Wow, I just can't put it any other way.

2. Practicing your turning.

3. Customization. You get *exactly* what feels good to you.

4. Saving money. I'd say I have all of 25¢ in the mallet pictured in this thread. I landed the walnut at an auction for $3. A cut-up stump from someone's yard, I think.


Nothing fits the hand quite so well as something you designed yourself, for yourself, and to your own personal taste. The wood is so cheap for so small a project that if your first attempt doesn't feel right, you just make yourself another until you have one you like. It's easy to keep costs down by gluing up a couple of pieces of 6/4 stock to your needed size.

Yep! Three bucks works for me. :)



So TJ, what made you decide not to bias the weight toward the top of the head and instead go for a more neutral balance?
Pure ignorance? :o
Honestly, I didn't give it much more thought until you mentioned it. Now I'm thinking it may have been desirable to weight the head near the top. <shrug> Live and learn. lol</shrug>

[Martin Shupe]

TJ,

Wonderful post! Thanks for posting all the pics and details.

[Pam Niedermayer]

Nicely done TJ. To my way of thinking, anyone who has access to a lathe owes it to themselves to make thier own mallet whether it's weighted or not....

True, but you don't need a lathe. A good drawknife and/or spokeshave will allow you to shape the mallet by hand.

Nice job, T.J.

Pam

[Cliff Rohrabacher]

Next time you get a yearning to work lead truck on over to the local tire store. Ask them for used tire weights. The local STS guy was happy I wanted his tire weights. I filled a few empty paint cans full of weights and for free.

[Ken Fitzgerald]

TJ...........excellent project! Beyond doubt that is the most useful, practical bonker I've seen! I surrender all patents that I might have had for any bonker designs! I've been outclassed!

[Bill White]

Probably 7 yrs. ago from dogwood. Also made some dogwood "gluts" or splitting wedges. Man, that stuff turns well and is so strong. Hard to imagine using a wooden wedge to split other wood. It is also heavy. Didn't need to weight the mallet.
Bill