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This is a badge bit (BB) that is part of the PEP curriculum.  Completing this BB is part of getting the sand badge in round wood working.

This mallet is similar to the club style mallet. However, this mallet is made out of two pieces of wood instead of one, and is also made by only using hand tools and no glue.

With this mallet, a dry piece of wood serves as the handle, fitting in to the green wood head (freshly cut piece of wood). The idea is that the green wood head will shrink and further tighten itself to the handle.

A hole is made all the way through the head, which the handle is inserted into.This should be a very basic and simply built mallet, able to be built pretty quickly.

Wooden mallets have many uses in carpentry. They can be used to hit wood pieces to join and fit together and can also be used to strike shaping tools without damaging the striking surface.

Be safe when using hand tools, work at your own risk, and enjoy building!

To get certified for this BB, post three pics.  

  - Your chunks of wood that you are starting with
  - Progress about half way through, with the hand tools you have decided to use for this
  - Final product

Look at the photos and videos below to get an idea of what the finished product should look like.
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master steward
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Looking for a youtube video that shows a quick block of green wood with a hole, and a dry peg that will be the handle.   So far, not having much luck.

I guess I would like this BB to be a pretty simple project.

I think i need to find some of the compound mallets we have here and take pics.
 
paul wheaton
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a google image search produced this:


(source)
 
paul wheaton
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This guy is starting with a dry head, which is the opposite for this BB



For this BB, it is critical to start with a fresh, green chunk of wood for the head of the mallet.   And a dry handle.   The idea is that the head will shrink and further grip the handle.

I also wish for this to be done without glue.
 
paul wheaton
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this one is kinda backwards:  dry head and green handle





this one also starts with a dry head.   But I like how with this one, there is emphasis on how the handle doesn't have to be straight!

 
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I like that, looks like what I was wishing to find, just was having a hard time finding it.

I'll update the above info.
 
paul wheaton
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how about this one?


 
paul wheaton
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here is a freakishly large compound mallet:




And the mallet below is freakishly happy, yet worn:
compound-mallet.jpg
[Thumbnail for compound-mallet.jpg]
 
Steve Thorn
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That is one big mallet!!! It looks one of those mallets at a carnival to play that giant mallet game. Maybe that could be in the straw badge!

I guess a well loved and used tool makes a happy tool!
 
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paul wheaton
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Sorry Nicole.   I am tempted to get fiddly about where you can use a power tool and where you can't, but a big part of this is the exercise of no power tools.  The hole is, therefore, either made with chisels or with something that is hand powered.  like this



https://amzn.to/2SGXaQC

 
Nicole Alderman
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I've actually wanted to get a hand drill for a long time. I've got some birthday/Christmas money, so I might put it toward that.

This one has pretty good reviews, and is 1/3rd the price of the one you linked to, but it this style harder to use?



This one looks like yours but is less expensive. Not sure if one brand is better than another, though...

 
paul wheaton
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Nicole Alderman wrote:looks like yours but is less expensive.



check the reviews.



There is also this:


https://amzn.to/2H6k3LW
 
Nicole Alderman
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My kids were fighting over their little wooden hammer...so I made them another hammer!
IMGP9918.JPG
[Thumbnail for IMGP9918.JPG]
My son picked a random piece of kindling for the handle. The head is from the big leaf maple I cut down for my simple mallet.
IMGP9947.JPG
[Thumbnail for IMGP9947.JPG]
Carved the peg (I ended up making it a bit narrower)
IMGP9954.JPG
[Thumbnail for IMGP9954.JPG]
Not having a hand drill, I just used a tiny bit, followed by subsequently larger bits
IMGP9964.JPG
[Thumbnail for IMGP9964.JPG]
Bigger bit (These bit pictures were taken by my 5 year old son)
IMGP9967.JPG
[Thumbnail for IMGP9967.JPG]
Even larger bit
IMGP9968.JPG
[Thumbnail for IMGP9968.JPG]
My little screwdriver wouldn't hold the giant bit, so I just wrapped it in a washcloth and spun it by hand
IMGP9970.JPG
[Thumbnail for IMGP9970.JPG]
Hole and peg done!
IMGP9973.JPG
[Thumbnail for IMGP9973.JPG]
Smacked it together with my other mallet
IMGP9984.JPG
[Thumbnail for IMGP9984.JPG]
My daughter approves!
compound-mallet-permies-kids.jpg
[Thumbnail for compound-mallet-permies-kids.jpg]
My son approved, too!
 
paul wheaton
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Nicole,

Does the handle go all the way through?
 
Nicole Alderman
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It goes half way. Some of the videos showed having it go all the way through, while other's went only part way. I chose the latter option, since it didn't seem to be specified how far one needs to drill into the mallet head.
 
paul wheaton
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A hole is made through the head



Nicole, no biggie, we are getting things started and it is good to sort this stuff out.  

A lot of the videos and pics are not a perfect fit - but give some impression.  

In this case, since we are not using glue and we are not putting a wedge into the end, we are taking advantage of the green wood shrinking around the dry stick.   So we need to give it plenty of stick to hold onto.   So the stick needs to go all the way through.

 
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Okay! I'll see if my husband can yank out the handle and I'll carve a longer peg on the handle and drill a deeper hole. (We had to yank the handle out once already because the handle split. I carved a new handle and inserted it.)

(My husband kept telling me, too, that I should have gone all the way through, but I interpreted "through" as meaning "into," rather than "all the way through")
 
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I made it all the way through! (Man, it was HARD drilling through that last bit with the giant drill bit. It kept getting stuck, and since there was no handle to hold, I had to keep undrilling it and cleaning the hole and starting again, only to get 1/2 crank before having to take it out again. I definitely need a hand drill!)
IMGP0040.JPG
[Thumbnail for IMGP0040.JPG]
Here's the peg, and the hole
IMGP0041.JPG
[Thumbnail for IMGP0041.JPG]
All the way through!
IMGP0045.JPG
[Thumbnail for IMGP0045.JPG]
The mallet is complete!
Staff note (paul wheaton):

I certify that this BB is complete!

 
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Paul, just to throw a wrench in the works... I found this video last night, which is a "ready-made" mallet cut from a tree whorl with the trunk as the head and a branch for the handle.
It seems to fall in the middle between the club mallet and the compound mallet, as far as skills and construction, but sure seems pretty darn Permie to me! Also sort of in the same vein as the coat hooks...
 
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