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+-- Thread: Two rejects to make one mallet part 2 (/showthread.php?tid=7322608)
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Two rejects to make one mallet part 2 - RonB1957 - 09-10-2016
The measurements were not very accurate but close enough.
![[Image: IMG_3230_zpsm4euybap.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3230_zpsm4euybap.jpg)
[/img]A 1/4" hole was bored into the head to match the handle followed by two counter bores for the tenon and bolt head.
![[Image: IMG_3226_zps9lqjoykp.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3226_zps9lqjoykp.jpg)
[/img]![[Image: IMG_3231_zps7ntin2lx.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3231_zps7ntin2lx.jpg)
[/img]A little bit of 2 part epoxy and........
![[Image: IMG_3232_zpsywyaqmdr.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3232_zpsywyaqmdr.jpg)
[/img]So after a while it was back to the lathe for some clean up. and the result....
![[Image: IMG_3234_zpsoc3dlga6.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3234_zpsoc3dlga6.jpg)
[/img]A bolt with a medallion head will pass through the mallet to make sure it never comes apart on me.
![[Image: IMG_3235_zpsrdjtip0y.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3235_zpsrdjtip0y.jpg)
[/img]![[Image: IMG_3236_zps7npmllqc.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3236_zps7npmllqc.jpg)
[/img]And there you have it. tomorrow is another day. Better I hope.
![[Image: IMG_3240_zpsalayg9uc.jpg]](http://i1179.photobucket.com/albums/x395/ronb19571/IMG_3240_zpsalayg9uc.jpg)
[/img]
RE: Two rejects to make one mallet part 2 - Cloudy - 09-10-2016
That is one sweet job!
RE: Two rejects to make one mallet part 2 - C. in Indy - 09-10-2016
Couldn't have been planned that nicely... well done!
RE: Two rejects to make one mallet part 2 - BaileyNo5 - 09-10-2016
That mallet is almost to pretty to use - very nice work. And that thru-bolt will make it nearly indestructible.
I've often thought about adding a brass collar/ring to a mallet, but so far all of mine have been one piece rather than two, so I haven't had the opportunity. Any reason the collar is inset rather than proud of the wood?
RE: Two rejects to make one mallet part 2 - Stwood_ - 09-10-2016
Sweet!!
RE: Two rejects to make one mallet part 2 - AHill - 09-10-2016
Leave it to a saw maker to make such an ornate handle! With a drawing to boot! I would only change one thing. I think I'd finish the handle with a satin finish. A lot of handling will likely dull the finish. May it provide you years of pleasure in use.
RE: Two rejects to make one mallet part 2 - RonB1957 - 09-10-2016
The brass ring ferrule came from an existing ferrule, and I don't have any stock greater than 3/4" dia in the shop right at the moment. Besides, I have several hundred of those sitting in boxes in my shop. They were made to fit a 3/4" x 3/4" tenon. The handle dim. were pretty much set as well. Just turned off some of the smaller dia. to blend better with the ring. I did color out side the lines again and added a few extra touches. A quick little problem solving distraction to give me a fresh look at a different problem.
Woodworking or the crafts in general, are always a lesson in problem solving using what you have at hand. BTW, I actually just weighed it. 16.4 0unces without the connecting rod. Looks like I got lucky. Shooting for 18 ounces. The finish is so shiny because it is wet. It will dry to a semi gloss.
RE: Two rejects to make one mallet part 2 - cputnam - 09-10-2016
Pretty cool!
RE: Two rejects to make one mallet part 2 - Pedder - 09-11-2016
That is a wonderful saving!
RE: Two rejects to make one mallet part 2 - JimReed@Tallahassee - 09-11-2016
That's what I call a real "whack job"! What a beautiful mallet!!! I imagine that every time you pick it up you will be reminded of its past and smile. Great work. Thanks for the pictures. I love the "how I shot the bear" progress shots.