Shopsmith Forums

Been meaning to make a mallet for quite some time(been using crude substitute(s)).

Thanks to forum member Buckeyedennis I acquired a piece of osage orange firewood for raw materials for the head.

Wanting it to be durable, I agonized over grain orientation, handle slit orientation(for wedge), handle grain orientation, wedge grain orientation . . . . .

I will discuss the grain orientation as this progresses.

The head needed to be tangential grain across the face of the head. Radial grain then goes from top to bottom of the face. That leaves what was vertical growth in the tree running from front face to the rear face.

After much futzing with the chunk of firewood, the jury decided upon a chunk taken out as marked.
The face has some checking, but I think CA glue will take care of any future problems with it(a compromise due to size of the firewood.

So a second view of the selected area to be harvested.
Cutting it out:
Then the blank was cut to size

The blank about 2 1/2 x 2 1/2 x 3 1/4. One face 90° and the other face 80°(10°).<<<<<< originally posted 15° which was the prototype angle which looked to severe.
TOP
BOTTOM

The hole for the handle was located at the center of gravity between the front and rear face.

The drill press stop was set to drill a 1" deep hole.
Drill 7/8" hole 1" deep.
Then two 13/16" holes drilled at a 4° angle into each SIDE of the original 7/8" hole with the bit even with the entry edge of the 7/8" hole. After first drilled, the blank is flipped and the other SIDE drilled at a 4° angle. Since the handle hole will be blind, the tapered sides provides room for the wedge to expand the sides of the handle.

That creates a hole 7/8" front to rear and about 1" side to side.

Now about the handle. Salvaged from previous handle making stuff. Actually it was a prototype that was made from micro-wave dried piece of locust that burned internally and the charing was not discovered until being turned. Hence it became a prototype and not the final version.

Now about it's grain orientation. The cathedral grain will be on the sides of the handle. Thus the tangential grain runs vertically. The wedge slit also runs vertically. The slit is cut almost 1" deep. That creates a wider handle as the wedge is driven in. The tapered sides of the head hole supplies room for the expansion. The hole remember is blind. Correct calculations recommended here.

Here is the hole with the 13/16" bit pilot showing a 1/8" spacing. Thus the hole sides are splayed 1/8" wider across the bottom of the sides.(actually slightly less)

OK now we need a wedge. A cutoff that will have tangential grain from side to side was first trimmed to create parallel front/back. It only needs to be 1" long.
Fortunately the checks are slightly further than 7/8" apart so cutting the first side.
Then the second side.
We now have a wedge blank that has rectilinear sides.
First square the end.
Next sand to wedge shape(about 1/8" over 1" taper.)(7°)
Next cut other side - the wedge will taper from about 1/8" to 0" over 1". Notice the wavy grain.
Now for the moment of truth! Will the handle be secure when it is driven into the hole and the wedge expands the handle sides as the wedge bottoms out in the hole.
The tape is where the handle should stop.
It seems quite tight. No rotation and no end play.

Show n tell time.

First the show.
Over all length is about 12 1/2".

Total weight is about a pound(the head weighs 14 oz).

The handle has a thumb groove just above the hand part.

The series of beads creates a second hand area for short handle tapping.

It may prove to be too heavy, but cutting the corners off will lighten it.

The CA seems to be taking care of the checks(and provided a finish as well).

The osage orange seems to be tear out prone when planing(on the jointer).

It drills much easier than I anticipated(forstner bits).

I think I am going to enjoy using it.

Now I need to make a new handle for my don't give a damn it I break it mallet.




!!!THANKS!!!

to Dennis and Charlese for their putting up with my grain worrisome pestering and Dennis for the raw material for the head.

Good job. I like it.

Very nice. Thanks for the tutorial.

Mike

Super! Looks like ALL your efforts paid off.

Doesn't look like the mallet will break any time soon.

Very nice descriptions and pics.

Like!!

Looks very nice. Nice photos too.

Nice mallet, nice post!

Really sweet!