#22
The measurements were not very accurate but close enough.
[Image: IMG_3230_zpsm4euybap.jpg][/img]
A 1/4" hole was bored into the head to match the handle followed by two counter bores for the tenon and bolt head.
[Image: IMG_3226_zps9lqjoykp.jpg][/img]
[Image: IMG_3231_zps7ntin2lx.jpg][/img]
A little bit of 2 part epoxy and........
[Image: IMG_3232_zpsywyaqmdr.jpg][/img]
So after a while it was back to the lathe for some clean up. and the result....
[Image: IMG_3234_zpsoc3dlga6.jpg][/img]
A bolt with a medallion head will pass through the mallet to make sure it never comes apart on me.
[Image: IMG_3235_zpsrdjtip0y.jpg][/img][Image: IMG_3236_zps7npmllqc.jpg][/img]
And there you have it. tomorrow is another day. Better I hope.
Smile
[Image: IMG_3240_zpsalayg9uc.jpg][/img]
BontzSawWorks.net
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#23
That is one sweet job!

Big Grin
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#24
Couldn't have been planned that nicely... well done!
Chris
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#25
That mallet is almost to pretty to use - very nice work.  And that thru-bolt will make it nearly indestructible.  

I've often thought about adding a brass collar/ring to a mallet, but so far all of mine have been one piece rather than two, so I haven't had the opportunity.  Any reason the collar is inset rather than proud of the wood?
True power makes no noise - Albert Schweitzer.       It's obvious he was referring to hand tools
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#26
Sweet!!
Steve

Mo.



I miss the days of using my dinghy with a girlfriend too. Zack Butler-4/18/24


 
The Revos apparently are designed to clamp railroad ties and pull together horrifically prepared joints
WaterlooMark 02/9/2020








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#27
Leave it to a saw maker to make such an ornate handle!  With a drawing to boot!  I would only change one thing.  I think I'd finish the handle with a satin finish.  A lot of handling will likely dull the finish.  May it provide you years of pleasure in use.
Still Learning,

Allan Hill
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#28
The brass ring ferrule came from an existing ferrule, and I don't have any stock greater than 3/4" dia in the shop right at the moment. Besides,  I have several hundred of those sitting in boxes  in my shop. They were made to fit a 3/4" x 3/4" tenon. The handle dim. were pretty much set as well. Just turned off some of the smaller dia. to blend  better with the ring. I did color out side the lines again and added a few extra touches. A quick little problem solving distraction to give me a fresh look at a different problem.
Smile Woodworking or the crafts in general, are always a lesson in problem solving using what you have at hand. BTW, I actually just weighed it. 16.4 0unces without the connecting rod. Looks like I got lucky. Shooting for 18 ounces. The finish is so shiny because it is wet. It will dry to a semi gloss.
BontzSawWorks.net
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#29
Pretty cool!
Thanks,  Curt
-----------------
"Life can only be understood backwards; but it must be lived forwards."
      -- Soren Kierkegaard
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#30
That is a wonderful saving!
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#31
That's what I call a real "whack job"! What a beautiful mallet!!! I imagine that every time you pick it up you will be reminded of its past and smile. Great work. Thanks for the pictures. I love the "how I shot the bear" progress shots.
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Two rejects to make one mallet part 2


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