The Mallet is almost done! Finally….
I was finally able to work a little bit more on the mallet this past weekend. All I need to do now is cut off the excess wood from the wedges and give it a final sanding and then apply some boiled linseed oil and it will be finished!
I cut the wedges for the top of the handle at 5 degrees. Next time I think that I will try 3 or 4 degrees.
5 ended up being just a little too big.
![](http://2.bp.blogspot.com/-ie4D0x6HwAE/UMfdemxloCI/AAAAAAAADq4/G1B7LX7bVK8/s400/07.jpg)
5 ended up being just a little too big.
![](http://2.bp.blogspot.com/-ie4D0x6HwAE/UMfdemxloCI/AAAAAAAADq4/G1B7LX7bVK8/s400/07.jpg)
I bought enough wood to make 2 mallets so this is the piece that I am going to
use to make the head of the 2nd mallet. It is the same species that I used for the handle of
my current mallet.
![](http://3.bp.blogspot.com/-9NyHlPBc0PA/UMfdfRSCbeI/AAAAAAAADrA/PMUSwxHqEVk/s400/08.jpg)
use to make the head of the 2nd mallet. It is the same species that I used for the handle of
my current mallet.
![](http://3.bp.blogspot.com/-9NyHlPBc0PA/UMfdfRSCbeI/AAAAAAAADrA/PMUSwxHqEVk/s400/08.jpg)
I bought a drum sander kit at Lowes to shape the handle. It is amazing what 50 grit sandpaper can do!
I shaped it with the 50 and then smoothed it with 80 and then 120.
![](http://1.bp.blogspot.com/-M3DKWGWCGbU/UMfdgfJqyrI/AAAAAAAADrI/aZFz1kMxuRU/s400/11.jpg)
I shaped it with the 50 and then smoothed it with 80 and then 120.
![](http://1.bp.blogspot.com/-M3DKWGWCGbU/UMfdgfJqyrI/AAAAAAAADrI/aZFz1kMxuRU/s400/11.jpg)
I filed the shoulder down a little so that the head would fit snugly and then sanded everything with
the orbital sander with 120 grit sandpaper.
![](http://3.bp.blogspot.com/-yNk6mu5V4FA/UMfdjY4plLI/AAAAAAAADrg/qKP94MsAOvo/s400/20.jpg)
the orbital sander with 120 grit sandpaper.
![](http://3.bp.blogspot.com/-yNk6mu5V4FA/UMfdjY4plLI/AAAAAAAADrg/qKP94MsAOvo/s400/20.jpg)
I glued the head onto the handle and then the wedges into the slots.