My old pellet filled mallet broke the other day and got BB's all over the shop. So I wanted and needed a new mallet. Since I really only use it for chiseling, I opted for a solid wood head as opposed to BB filled.
I took a piece of Padauk I had and matched it's size with some Maple. I trimmed them up to roughly the same dimensions and glued them up. I did the same for the handle using just the Maple.
After everything was dry I trimmed up the ends and faces of the head and just the ends of the handle. In the head I wanted the handle to sit inside, so using a forstner bit I drilled down about 3/4" then using a slightly larger bit I went all the way through. MUCH easier to do when the blank is square and not round. :)
Using my lathe chuck I turned half the head at time. It worked OK, next time I'll probably just use the spindle. Then just a lot of turning.. and turning.. I sanded up to 220 and threw some wax on.
Then I turned the handle to a comfortable feel and got the "peg" and where the head and handle meet to be pretty flush and tight.
I put a slice in the top to accept a wedge. Using a cut off of Padauk I glued and wedged everything up. Trimmed the top and voila!
Woodturning a Mallet on the Lathe - • Woodturning a Mallet o...
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King of Prussia, PA
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