Wood Turned Carvers Mallets

I have made a batch of wood turned carver’s mallets. Each is made from 2 pieces of reclaimed tropical hardwood. The hardwood used for this piece was originally ship dunnage used under steel that was shipped to the Port of Portland, Oregon. The joint between the 2 pieces of hardwood, attaching the handle to the head of the mallet, is a radial finger joint. I cut this joint on the CNC router. After wood turning the mallet, it was sanded to 1000 grit and finished with walnut oil.

Mallets: making more

Music: https://ampletunes.com/

Some of the tools used in this project
CNC: http://www.cncrouterparts.com
wood turning tools: http://carterandsontoolworks.com/

Cantilever Clamps: http://amzn.to/1TJmAFx
Milwaukee 4-1/2-Inch Angle Grinder: http://amzn.to/1WF6QKk
Milwaukee Close Quarter Drill: http://amzn.to/1sj7bGj
Milwaukee 18-volt Compact Drill: http://amzn.to/1sj855F
Metabo Random Orbit Sander: https://amzn.to/2Ebp4Aw
Whiteside Router Bits Compression 1/4-Inch: http://amzn.to/2pV9ouk
Router Bit 1/4-Inch Down Cut: https://amzn.to/2piSkw5
Oshlun 8-1/2-Inch Negative Hook Finishing ATB Saw Blade :http://amzn.to/1TJmTQJ
Freud 8-1/2-Inch Saw Blade ://amzn.to/2qtNTfT
Amana 16 Inch Saw Blade: http://amzn.to/2n34xVN
FastCap Glu-Bot Glue Bottle: http://amzn.to/1TJn0vq
3M Peltor H10A Optime 105 Earmuff: http://amzn.to/1sj80iw
3M Reusable Respirator: http://amzn.to/2cGwyPL
3M Particulate Filter P100: http://amzn.to/2bYwhaK
Oneway Stronghold chuck: http://amzn.to/1VViyjO
Milwaukee 4-1/2-Inch Angle Grinder: http://amzn.to/1WF6QKk
Walnut Oil: http://amzn.to/2BRqONH
Vick 3-Piece Set: http://amzn.to/2iK7SHY

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42 ответов на “Wood Turned Carvers Mallets”

  1. You know, Frank, whenever you post a video there's this "I know I am about to watch a beautifully engineered piece of work" feeling. Either the workpiece or the thought you put in or around it or the filming or editing, stop motion or any possible combination of the above. And then you somehow manage to blow me away by going anywhere between a step and a mile further than that assumption.
    Amazing!!
    I am so thankful for the joy and creativity you bring to us. Please keep going!

  2. A thing that's making it slightly more cumbersome to fit the two pieces together is that there's no such thing as a perfectly sharp interior corner. Since you're cutting all of these surfaces on the CNC, what you could do is as a last pass take the endmill and profile out about 2mm in, and 2mm down, maybe less on the tips of the fingers far enough in that it definitely won't be exposed. Ideally you'd use a V bit endmill to do a chamfer, but that's a tool change. Cutting a little notch out of the finger tips creates just that bit of space so you're not trying to shove the sharp exterior corner of the finger tips into the interior corner on the other piece.

    Even if you actually cut a super sharp interior corner there's glue and general stuff and what if there's a slight burr on the finger and suddenly it's not sharp, it's full of stuff with nowhere to go, give it a chamfer or a notch and the imperfections have a place to go so that it's not a problem at all

  3. It's a great design, but the level of surface quality isn't in keeping with its function as a utilitarian object. I don't want to feel bad about messing up the hour-long, 1000 grit surface the first time I whack on something with it!

  4. Those mallets look awesome! Remind me of some chess pieces with the way that joint is.
    One thing that should help you in the future with a batch project like this is a contour sander (set). Basically pit a piece of wood in the lathe and make it into a shallow cup. Glue some sand paper on the inside and now you can just stick the end into it to shape it. Rocking the piece side to side would make sanding faster and drilling some holes in the cup would help to get rid of sanding dust. Then for finer grits flatten a piece and adhere a piece of yoga mat between it and the sandpaper to make a padded disk sander.

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