Carving Mallet Prototypes (Part 1) The Tease

David, my machinist friend, has been working on finding tools and materials to grow his machining capabilities. Over the years he has acquired a small and large shaper, a nice drill press, a small and large lathe. All of his tools are old school for the machining industry, but that is what he likes. As he has puts it, he likes to turn dials.

The big lathe is his latest acquisition, he had watched Craigslist for quite some time before he opted to get this one. It required a road trip to the northern edge of Wisconsin, it was literally a few miles from the border of the UP. It was an enjoyable trip with him and his dad. I went along for extra muscle and conversation – or  mainly just conversation.

After some cleaning and playing with his new machine, David has put it to work on a couple of prototypes. I had requested he consider making some brass mallets and here are some of the steps he has experimented with in their creation.

Facing the end.
Facing the end.
Creating the taper, notice the nice curly metal coming off the tool bit.
Creating the taper, notice the nice curly metal coming off the tool bit.
After taking a file to it.
Shiny after filing.
After sanding and steel wool.
After sanding and steel wool. Lots of glare!
First center drill
First center drill.
3/8" hole 7/8" deep.
3/8″ hole 7/8″ deep.
Final drill.
Final drill.
Parting the mallet head from the bar stock.
Parting the mallet head from the bar stock.

He’s done a fantastic job! I can hardly wait to get my hands on these mallets and try them out. I am hoping he will consider making a production run of them to sell. If you know anyone who might be interested in one, please let me know!

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