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Club style mallet - PEP BB roundwood.sand.club

BB round wood woodworking - sand badge
 
master gardener
Posts: 2603
Location: Upstate NY, Zone 5, 43 inch Avg. Rainfall
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Minimum requirements:
  - roughly 16" long and 4" diameter at the fat end
  - handle that you can comfortably hold
  - handle is smooth enough that you won't get a splinter using it
  - made with hand tools only

To document this Badge Bit, provide proof of the following as pictures or a video (<2 mins):

  - Your chunk of wood that you are starting with (about 16 inches long and 4 inches in diameter)
  - progress about half way through, with the hand tools you have decided to use for this
  - final product held in your hand showing that your thumb and first finger can touch (any fatter than that and your hand will get very tired using it)


So everything went wrong with this BB when it came to prep. My draw knife is in my shed which is packed tight for the winter... Along with my hatchets.


I used a wood carving knife and a tomahawk to complete this BB. I had to get over worrying about taking too much wood because taking only small pieces was taking forever. Once I started swinging, the handle came together really quick.
Bonker1.jpg
Piece of a Box Elder
Piece of a Box Elder
Bonker2.jpg
Width
Width
Bonker3.jpg
Debarked
Debarked
Bonker4.jpg
Hawk is 22"
Hawk is 22"
Bonker5.jpg
The Bonker 5000
The Bonker 5000
Staff note (gir bot) :

Someone approved this submission.

 
Posts: 81
Location: Shenandoah Valley (Virginia) Zone 6b
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Took me about two hours to make this mallet—including sawing the chunk of wood from a cut branch we brought down a couple of weeks ago, shaving off the bark with a hatchet, chiseling the handle out, smoothing it with a pocket knife, and then sanding the handle.

Ah well, never done this before.

I made myself a stand / holder with two concrete blocks, so I could sit on a low chair to work and also so the blocks would hold the mallet while I held the chisel with one hand and my (bought) mallet with the other. Without that, it would have taken me a lot longer.

Also, I checked that all the tools were sharp before I started using them.

Next time, I wouldn’t be afraid to take off bigger chunks of the handle with the chisel. My hand is pretty small, so it would have gone faster if I’d been less delicate at this stage.
D9E982FA-A3FD-40CD-8E96-1039CFECA173.jpeg
section sawn from branch
section sawn from branch
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debarking with hatchet
debarking with hatchet
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sawing where handle ends
sawing where handle ends
4435A9CC-D75A-4515-A1D1-33689D01A9B6.jpeg
chiseling handle
chiseling handle
BA60F392-BB17-46E2-8DC1-64ADCDD164AE.jpeg
smoothing with knife
smoothing with knife
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wedged with other mallet to sand handle
wedged with other mallet to sand handle
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finished mallet
finished mallet
F5D5BA09-DFE8-48DA-924D-7861FEC2D362.jpeg
tools I used
tools I used
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Someone approved this submission.
Note: This BB is complete!

 
Posts: 1
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Had a white oak fall due to a storm and decided to make use of the windfall. Started with a hatchet, switched to an axe. Then, after the handle was roughed out, switched to a knife. Finally, I cut off the excess with my bow saw.
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Timothy Norton approved this submission.

 
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I used a length of a cottonwood branch that went down in a storm and my hatchet.

First time making something like this with a hatchet- I found it to be kinda fun.

I have small hands and wanted a 2 handed mallet so I left the handle good and long.
20240309_101416.jpg
green cottonwood
green cottonwood
20240309_110350.jpg
super long lol
super long lol
20240309_110251.jpg
about 4" after the thick bark and easily peeled layer are off
about 4" after the thick bark and easily peeled layer are off
20240309_103507.jpg
getting the hang of it!
getting the hang of it!
20240309_124545.jpg
small enough handle for my hands to control
small enough handle for my hands to control
20240309_124601.jpg
other end of the long handle is small enough as well
other end of the long handle is small enough as well
Staff note (gir bot) :

Paul Fookes approved this submission.
Note: I certify this BB complete.  Well done

 
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