Hey all,
I scrounged some scrap materials from the recycle bins at work and came up with 3 of these mallets. The head is bronze and about 1 1/4" diameter by 2" long while the handle is a piece of titanium and about 3" long. The overal 5" length fits my small to average size hand quite well. The 2 parts are press fitted together, no threads, screws or bolts to come loose.
After assembling the first one I bored out the center of the handles on the next 2 to make the head a feel bit heavier but all three have sufficient heft for carving/chopping operations. The 2 with the bored handles weigh ~18oz and the third is ~19 oz. Not a big differance.
I machined 2 flats on each head, 90 deg. apart for 2 reasons. First, it gives me a place to rest my thumb and reference the other flat if i want to strike a chisel that way. As you know, most chisels have rounded handles and striking one with a rounded mallet can cause glancing blows and the flat helps avoid that. The second reason is it'll keep the mallet from rolling off the bench and onto my foot. DAMHIKT!
All in all, i'm happy
Thanks for looking!
Brian
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