Hi, this is Wayne again with a topic “Diresta: Gold Ring Mallet”.
Okay, I’m making a mallet out of 2-inch thick white oak, the white oak. I got from a sawmill in Woodstock New York, it’s been drawing for a really long time, and the surface still has the bandsaw marks in it, which I need to remove, which is why you need planing it there just want to get it flat, even though I Got it flat, there’s still a little bit of a twist in the wood, which is why I kind of play it safe with the table saw and I have it cut halfway up and then halfway up, I was afraid it would bind if I try to make A full depth cut, you can see it rocking around a little bit and that’s because it’s got two twists in it, but it’s going to be gone. It’S not important right now. This is going to be the two halves of the head of my mount, and this is the first piece I cut in the opening scene. It’S going to become the handle to the mallet, and Here I am just laying out the sides and then the taper.
I’M copying a mount that I had many years, but it’s been broken, so I’m kind of remembering the shapes of it and then that is the taper and then song it. It’S a safe, safe bet to use the bandsaw when I’m making a compound curve like that, like that, like that, it’s uh there, you go just been sawing it and that taper obviously is the most important right there. So I’m going to sand it a little bit and just follow down line. I have like a really really sharp line.
It’S at a focus, but it’s there now here, I’m kind of taking the safe approach by making a the pocket square first and then geometrically. I know that it’s parallel to to the universe of the mallet and then I’ll add the taper in it. So it’s easier for me to go from a square and then add the taper. So that’s what I’m doing now.
It’S basically making us perfectly square channel down the middle of the mallet head. I was being able to get into it on either side yeah, so they’re straight and straight, and so then I’m able to geometrically make the accurate taper and I’m using the sled and by me putting a chunk of wood onto one side. Of course, I may try to the size of the chunk, I’m able to kind of kick it up into the angle I need, and then I use that same chunk for the other side and it’s just a quick way to be able to make that angle.
Work and I’m also using the cut line in my sled as a guide, so I know I have the marks coming up and they’re visible on each end. Now, I’m just in the test fit, and now, if I cut the next one and there you go just by having the chunk of wood, kick it up. It gives me a few degree angle that I need. I don’t even know exactly what that angle. Is it just kind of freestyled it and it’s what I make sure the tape is, are the same so that the mallet head, oh, that the mallet handle fits into it.
Now, that’s I’m just using my Veritas shoulder plane to clean out the saw marks and make it nice and flat and there you go and it kind of fit together in one way perfectly: that’s why I’m flip-flopping everything around and there it is making sure I remember How it goes, and now I glue it she’s a type on type on wood glue and just get it on the surfaces. Then I just use screw clamps just to get everything nice and strong screw clamps are, I think they look good on camera, but they also work really well can never have enough – and Here I am – I’m gon na put a little bit of a round over on That handle – and I don’t want it to go all the way across all four sides – I’m just trying to get that that round over to appear on two sides of a handle and you’ll see what I mean in a minute. So I’m going slow and just putting this I’m going to be the hands almost end right there and just working it slowly. When it comes to lathe work, I go as slow as possible until I can get to where one now, I’m.
Finally, where I need to be and I’m using a very rough paper, and now I have to I’ve spun it – I kind of sand it straight just going to do it on the head as well. It’S really nice whirl marks which are kind of hard to avoid when what is spinning and you’re sanding it so there I am, and I think I’m liking it just do a test fit now. The glue is drying on the mallet head, fits really good and now it’s time to work on that find the center, which isn’t hard. Now, I’m going to I’m going to jam off the corners, because I don’t really like turning a square, although it’s possible, it’s just.
It’S a lot of extra work when I can just cut that off on the bandsaw, just give myself the guides and then my bandsaw set to 45 degrees, and I can just rough off the corners. It makes the make some legs work a lot easier and it’s a lot quieter. Lai’S working, a full square is real, annoying and yeah. Now it’s doing the legwork and I’m off and like I said this is a I take it slow.
So you see me stop several times and make sure I want to go past where I need to when it’s spinning it’s very deceiving. It looks perfect and when you turn it off, it looks unperfect, so you got to keep checking and a little chip out in the holes see the hole that the handle will go through so off-camera. I squirted some crazy fool around the hole just to make sure that I wouldn’t chip out as much as it was doing Krazy Glue kind of secures the fibers in place and now I’m getting ready to put my my impressions where the Rings are going to sit. I’M going to put brass rings at each end of the hammer and I’m going slowly.
I have my calipers to make sure that I’m going to be the right there and it’s just under three inches to see outside damage or the brass is three inches and just check, and I leave it a little fat right now so now I could always take It off later and now, I’m working the other side and I played safe, but just taking a little piece off a little piece off. Until I get to my side, I want a little piece and then I catch up with more, of course, one somewhere. I want to be – and I use that as my reference, that little shoulder and now I’m going to work the rest of the mallet back inside the curve to try and bring it back in visually, just right now, just a big lump. So I’m working there at the body, they’re just sort of a football shape and just working it and working it final, different Illinois so never know exactly, which is the right tool for the job.
Unless, of course, it’s squares, it’s another two easy decision, but your left foot I would little scrap chisels and then clean it up with the bigger ones and then sandpaper always helps and, like I said earlier, no matter how fine a grit you use. You always end up with swirl marks, so regardless you always got to go back in I’m just doing a test fit. That looks good. Obviously I didn’t spin it with that on there now take it out and just send the hell out of it, get it where I want and then once I’m done, sanding it with the swirls. I try and get all the spin marks out of it by just going parallel to the grain I’m happier now. This is a 3 inch breast to Bajada by 10 feet of it.
I really needed a foot of it when I first bought it for a lamp, and I knew it would be the perfect diameter and I cut the first piece off because it’s dented and I cut two more pieces off about 1 inch thick and that’s super easy. There you go and they see my two rings and they’re just taking over the sander and I’m just using the reference of the side as square, and you know that you cut them squared and it crooked, but I’m using the reference of the bottom. So if you see me pushing inside the bottom of the ring is to make sure the bottom is flat against the table and I put a little chamfer on the inside of one of each of the sides so that when I bang them on now, when I Made that the receiving ends on the mount I tapered them a little bit so they fit on initially, but then I have to bang them on more and Here I am banging them onto the anvil, bang, bang and I’m going slow, just watch the mission up and Braking and it really seated nicely – and I had all my measurements are really close, and then I take it over to the sander and then I just kiss off the faces of the nice and clean. This is a type of mallet that you’ll use for like mortising and stuff like that, so those rings, obviously we put dents in, would if you were planning on banging onto it, but it’s really just a like a chisel mallet. I put a little uh convex on the end of the top of the handle just to kind of make it fit with the football shape and I’m using scotch brite to clean up the Rings.
Just get the sharp edge off. I’M proud of my work and I’m just using BRE wax just to seal it and keep my finger prints off it and proud of my work. I’M happy the way this came out.
I was really not sure what to expect. I had a vision and I was able to hit it right on the mark. So doesn’t happen every time, and this is just paying homage. I think it was a an old movie logo used to do this and I just thought it would be a funny thing to do and that’s my mark and there’s my mallet thanks for watching.
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