Compound mallet - PEP BB roundwood.sand.compoundmallet

Nicole Alderman wrote:Rob, could you show me a picture of the top of the mallet? (I only ask because I didn't get my certification the first time because my handle didn't go all the way through the head).

Thanks!

Oh, I didn't catch that.   The handle doesn't go all the way through.  Also regarding the green head, I cut this green but left it aside for a month, carried away with other things. I'm not super happy with this mallet anyway so ill redo it., and double check the requirements next time. Thanks!

Nicole Alderman wrote:Rob, could you show me a picture of the top of the mallet? (I only ask because I didn't get my certification the first time because my handle didn't go all the way through the head).

Thanks!

Mike Haasl wrote:For this project, the head needs to be green wood (fresh) and the handle dry wood so that the head shrinks and grips the handle.  That's also why the handle needs to go all the way through.  If it doesn't, the head can't shrink around the handle all the way through the head.

I'll tweak the format of the top post to make that a bit more clear...

Thanks for bearing with me.  Here is a mallet update, and I think it's much better.  

I present M.C. Mjolnir:


Note--the piece of wood I used for the handle was just a little bit too big, and crooked in a way I didn't like, so I switched it out for one slightly less crooked and a little thinner.  I did not peel the bark off any of this.

I made this with the following hand tools, some of which may not have gotten a cameo:

--small chisel, now half broken
--a screw (used as a rasp or a hole maker to start the hole straight, NOT as a fastener) and a nail (for similar reasons--this really sucked when it got stuck)
--a power tool drill bit, with a screwdriver head (no power!)
--a flathead screwdriver (as a chisel--didn't work out well for the screwdriver either)
--some cinder blocks to hold things up at some points
--some clamps
--no tools that would have actually made the job reasomable, such as a full-sized chisel or hand drill, a better claw-tooth hammer for getting the nail back out)

I learned a lot from this process.  I started this mostly from curiosity about whether I Could actually pull this off, and it's been more illuminating than I anticipated.  I think I am going to go for the full badge and make a stool next, since life has handed me green wood!

Nicole Alderman wrote:By "hand tools," does that mean one can use plug-in/battery-operated drill to make the hole for the handle?

Speaking as a participant, "No."  Hand tools mean human-powered tools.  No batteries, no power cord, no generator, etc.  Saying that we need to use the tools we make in metalsmithing is going to extremes.

When I read this BB, I immediately thought of the offset-style "manual" drill even though I have several power drills, drill presses, and a battery-operated drill.
There is also the crank-style drill, the auger, and the hand-crank drill-press.  Apparently, our offset-style drill is in deep storage (another term for lost) but our search turned up an auger that needs sharpening and the hand crank drill press seen below.

I'm planning to try the auger if the hand crank drill does not have enough depth (space between the platform and drill bit).

I'm seeing a number of cases where people are really struggling to make a hole without the ideal tools.  If you have a thrift shop or do some garage sale hunting, you can find auger bits and braces (second picture of Nicole's) and they'll make it MUCH easier.  I found two braces at a garage sale two days ago for $4 ea.  At least one is coming with me to Wheaton Labs as a gift.

An auger bit for a power drill can still be used manually with a vice grips or other clamping tool.  So if you did invest in one it could be used for those wiring projects in the Electricity badge (running wires through studs).

$17 auger bit set from Harbor Freight

Here is my submission for the compound mallet roundwood BB.

I have included four photos for your review:

 - My chunks of wood that I started with (the short one is clearly green and the long one is dry) with another compound mallet made by a friend.
 - Progress about halfway through - drilling with the hand auger
 - almost finished with the hand tools I used for this
 - Final product

I thought I'd hammer this out real quick.

Boy, was I wrong. Part of it was the wrong tools, though.

Here is my submission for the PEP Badge - Compound mallet. This will be my first badge so I'm looking forward to have finally started my journey!!

For my wood I selected an old piece of Crape Myrtle for the handle and a shrubbery root that is trying to turn back into a bush for the head. I trimmed the root to something manageable. I drilled the hole. I do not recommend this brand of hand drill. The chuck is garbage. I used my club mallet to pound the handle through.

Compound mallet. Green head, dry handle.