I have been saving a large hunk of
copper round stock for a very long time, and I finally found a use
for part of it. The top ring is a ½” thick, and the bottom
ring is ¼” thick. I had Marv make these ½” smaller in diameter
than the leather would be. The thickness provides the mass for
the mallet. It would be too light without these.
I also had Marv make an arbor for me to
turn the leather discs into the cone shape I wanted. The arbor
allowed me to glue the discs together so I would not get them mixed
up when I put them onto the metal shaft. It also allowed me to
compress the leather.
Here the assembled cone has been
turned, and it is still mounted on the arbor. I used a very sharp
scraper to turn the outside.
The tool above it is an antique washer
cutter that I have had for a long time, and this is the first time I
have ever used it. It is a wonderful tool.
Here the washer stack has been
installed onto the metal parts, and it is waiting for me to make a
handle for it.
Here is the handle stock. Teak for me, and purple heart for Marv. He
will most likely just display his, whereas I will actually be using
And here they are in all their radiant
beauty. I used only wax for a finish. I do not like film
finishes on my handles. You will notice that I decorated the
handle on Marv’s mallet. Mine was left plain.
This project was a lot of fun to make,
but I can’t recommend it to anyone else simply because of the amount
of skills and tools required. I am certain that a simpler mallet can
be made, and that I can heartily recommend. I have been wanting this mallet for a
long time, and now I finally have one.