As a coffee lover, I've got coffee hardware to match. 27 kilograms of chrome coated coffee extraction goodness on the kitchen sink, baby. We're not talking drip coffee. No, no. This coffee gets made a 10 atmosphere. Es-press-o. The coffee grinds remaing in puck, after having created a tasty cup of coffee, usually need a fair amount of convincing (smashing, hitting, whacking) to drop out of the portafilter. Some people have a so-called knock-box for that. Not the docter Seus type, but a shiny metal box, sometimes placed under the espresso machine, with a rubber-coated bar in it, on which to whack the portafilter until the coffee grinds drop out.
As I have fairly limited space in the kitchen, I prefer not to have yet another big kitchen utensil for coffee making in there. So for removing coffee grinds from espresso portafilters, I have been using a wooden mallet. My so called coffee-puck smasher. This small walk through shows you the steps I made to create a replacement mallet for my old and smashed-to-pieces coffee-puck smasher.
The size of the mallet described here: 5.5 x 10 x 17 cm.
- jigsaw with wood blades
- electric sanding machine
- dremel with cylindrical wood sander
- small ruler
- a hair dryer (or anything able to blow hot air)
- bees' wax / sno seal / mineral oil
- a block of strong wood big enough to make a mallet from (10 x 6 x 15 cm. or bigger)
Step 1: Preparations; Find Wood
What size must the mallet be? Just make a mallet big enough so that it has enough mass to do the smashing you want it to do.
Step 2: Make the Design
Step 3: Cut Out the Initial Shape
Step 4: Shape the Handle
Step 5: Rounding the Handle
NOTE: Try to use a suitable tool for this. I won't tell which tool I used because it is way too dangerous (hint: it starts with a "J")
Step 6: Make It Nice and Smooth
You should now have a mallet looking and feeling nice and smooth. The texture of the wood should stand out nicely.
Step 7: Waterproof It
To apply the wax I did the following:
- using the sponge in the pot of Sno Seal, bring on a layer of wax on the mallet
- use the hair dryer to properly heat the entire mallet for about 3 minutes
- watch the wax melt and soak into the mallet
- repeat about 4 times
- let the mallet cool down
After this, I had a mallet which was waterproof. I was afraid that the handle might be a bit slippery due to the wax, but fortunately it wasn't.