Make your own tools- Dead blow Mallet

[BillK]

This was a fun project with useful results. My dead blow Mallet made from Red Oak. The head is carved on both sides and the handle also. The insides of the head has two 1/2 inch deep cavities which are then filled with steel balls at about a third of the volume. The handle top is butterflied into the two mallet halves, epoxied and doweled, in other words, it ain't movin'. Four other dowels and glue hold the head together. The head is about 4x6 with angled faces and 3 inches thick. The handle 1x1 3/8x12 inches proud. Eased the handle edges on the router table with a 1/4 inch round over, the head with a chamfer bit. Everything else done on the shark.
Check my facebook page (link below) for a video of the deadblow action.

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Prior to assembly

[Bob]

Nice work Bill!
Another great example of using the Shark to make tools.
Bob

[tonydude]

Nice Bill. You're always coming up with something unique.

Tony

[BillK]

Thank you very much Bob and Tony, my fellow Sharkologists.

If any of you other 80+ readers have a question, please fire away.

[basecircle]

Bill what can i say .Very nice Basecircle

[dmyers]

Bill, very nice.

Would you be willing share your files?

David

[WoodEraser]

Now that's thinking out of the box!
Thanks for sharing.

[regrant3]

Only one problem with your design. It looks to good to use.

You do extraordinary work.

[BillK]

Thanks one and all.

dmyers, yes, I can add the basic files of the profile cuts, etc but not my deer or the celtic weave. I never think to post my files because I think everyone enjoys the design phase as much as I do. Give me a day or so.

I'm in the process of designing a slightly smaller, more decorative version that I'm giving as a gift.

[dmyers]

BillK,

Thanks, I understand. I'm just interested in the mallet it self.
I have a friend who sculptures and I would like to give it to him (personalized) as a gift.
I'm sure he would probably display it rather than use it.
But again, great design.

David