In this Instructable i'll show you how i made a Dead Blow Mallet on the Lathe, hope you find some inspiration to make your own!
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Step 1: Gather Your Materials and Tools
- Tablesaw or Hand Saw
- Planer ( not necessary)
- Wood Lathe ( of course with tools)
- Jacobs chuck for the lathe
- Tape measure
- Forster Bits
- Disc Sander ( or just sand by hand)
- 8"x 3"x 3" (20cm x 7,5cm x 7,5cm)for the head and 2"x 11" (5cm x 28cm) DRY Wood
- Boiled Linseed oil
- Lead Shot
- Wood Glue
- 2 part Epoxy Glue
Step 2: Cutting the Wood to Rough Size
I used some Reclaimed Plum wood for the Handle and the head for the mallet, the Caps that are getting the most abuse are made from Hornbeam which i found in my firewood.
I cut the head to a length of 5" (13cm) the two caps are 1" (2,5cm) the diameter of all is 2.5" (6.3cm) this is the finished size. the handle is cut to a length of 9" (23cm) by 1 1/4 " (3,2cm) also finished diameter. So cut your stock oversized due to loss on the lathe.
I needed to flatten and square up the piece for the handle because mine had some big cracks in it. Afterwards i cut out the usable part with my tablesaw. ( you don't need to do this if your material is in good shape)
Step 3: Turning the Handle
I turned the handle between centers to give it a shape that fits my hands. Afterwards i turned down the part that goes in the mallet head to 1 5/16" (3cm) which matches the size of my Forster bit. the handle goes 1 1/2" (4cm) deep , so this is the part that you need to glue in the head.
After sanding the handle to 220 grit i took it from the lathe and laid it to the side.
Step 4: Turning the Head of the Mallet
Next i turned the head round between centers, made a tenon that goes in screw chuck on my lathe and gave it a light sanding. Afterwards i drilled a 1 1/2 (38mm) diameter hole that goes 1" (2.5cm) deep from both sides, so that there is enough place when you drill the hole for the handle ( which matches the part of the handle) don't intersect with each other.
Afterwards i marked the center on the Mallet head and drilled the hole with a 1 5/16" (3cm) Forster bit 1 1/2" (4cm) deep.
Step 5: Turning the Cap for the Head
I roughed out the hornbeam wood (again) with my Carbide turning tools, marked out the areas which didn't got cracked because the drying, and established a tenon on the end so that i could chuck them up without a tailstock support. I turned the wood down so that it fits snugly into the mallet head about 8/32 (6mm) deep. i repeated this step also for the 2nd time after i cut down the 1st cap.
Step 6: Adding the Lead Shot and a Last Bit of Turning
I have measured out the amount the Shot that fits in the hollowed out part so that the cap seats well and it don't rattles to much. i filled up one side and glued on the one cap with some wood glue. Afterwards i turned it over and repeated this step.
For applying some Clamping Pressure i used the lathe but without the live center to avoid the pressure mark which the point of the live center leaves.
Afterwards i turned down the caps to get a constant thickness and diameter. with the turning part finished i sanded the head to 220grit and parted it off.
Step 7: We're Almost Done Just a Bit More....
I used my Disc sander attachment for my lathe (you can find the video how i made it here ) and sanded the head and the handle to remove the points where they where attached to the lathe.
Afterwards i mixed some two part 5 minute epoxy, applied it to the mallet head ( not the handle) and inserted the handle in it. After 1hour curing time i applied some Boiled linseed oil to protect the Mallet and give it a nice finish.
Step 8: Enjoy Your Beautiful New Mallet
After applying several coats of linseed oil ( after the previous coat was dry) The Mallet is finished!
I hope you enjoyed this article and found some inspiration to make your own and if you want to see more great projects you can subscribe to my YouTube channel!
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BigAndRed made it!