A mallet for morticing

**derekcohen** · 11th November 2013, 01:01 AM

Over the years I have used a number of different mallets to pound a mortice chisel. The search may have ended.

Until about a year ago I was using one of Dave Jeske's (Blue Spruce Tools) ...

This is beautiful to look at, beautifully made (as is everything he makes), is a pleasure to use with bench chisels, however at 16 oz it is too light for a mortice chisel into hard woods.

For morticing I preferred either a Thor (about 20 oz) or the Veritas (19 oz). While not significantly heavier, they focus the downforce and this is more efficient.

Here are the Thor and Veritas alongside a long-discarded Marples (only 14 oz).

The Thor is a great mallet. I purchased it for convincing furniture parts to get closer together with each other, however it makes a great mallet for chisel work when wanting to work quietly or reducing vibration. The downside it that it looks like something that a motor mechanic would use .. which is where the Veritas comes in. The Veritas is a good design. My only gripe (easily fixed) is that the handle is a little too slim for my hand. I want this to be longer as well, but that probably reflects the mass/downforce limitation. It would be great to see a 2 lb version of this hammer produced for morticing. Rob, are you listening ...?

What I want in a mallet for morticing is something that has about 32 - 38 oz, is relatively compact for this weight, and will not damage the unhooped wooden handles of a Western mortice chisel. This would not be an issue if I used Japanese mortice chisels as I have a few gennou, including one that is 450 gm (16 oz). Interestingly, this lighter hammer seems to have more downforce, possibly because it is focused on a small area? The problem, however, with steel-headed hammers is that they destroy wooden handles. I'd rather replace the mallet than the chisel handles.

What brought matters to a head this weekend was the recent release by Blue Spruce of a 24 oz Joiner's Mallet in infused acrylic (which should make it indestructible).

It has been given two thumbs up by Chris Schwarz ..

Highly Recommended: Blue Spruce Joiner

So why didn't I just order one? Well I am still waiting for The Chair to arrive so I may complete my measurements and start building one (hopefully tomorrow!), and I had time on my hands and a plan in my head ...

Put me in front of a bench with spokeshaves, rasps and a few scrapers, and I am as Happy as Larry (translation: As happy as Larry).

A bit of Karri for the head (heavier and more interlocked than Jarrah) and Curly Marri for the handle (softer, "chewy", I think will absord vibration well), and bit of brass ... This is what I came up with ...

The faces have leather for cushioning the chisel handes. The mallet handle is oval in cross section, approximately 1 1/2" x 1" and 10" long. The head is approximately 5" long x 3 " high and 2 3/8" wide.

The overall weight of this mallet came in at a little over 38 oz. How did it manage this in a relatively small head? It is down to the 1/4" thick brass plate that was added (peened) to each side ..

In use this mallet is in a different class to the others for morticing. It It certainly helps in punching the chisel through hardwoods ...

Regards from Perth

Derek

**ac445ab** · 11th November 2013, 01:27 AM

Hi Derek,
very nice your mallet. I like the choice of adding a brass insert.

**derekcohen** · 11th November 2013, 08:33 PM

Thanks Giuliano

Today I replaced the leather on the mallet heads with pieces off an old horse butt strop. This is about 1/8" thick and firm. It is attached with hide glue, of course

Regards from Perth

Derek

**lesmeyer** · 11th November 2013, 10:55 PM

Derek, absolutely beautiful and most surely great to use. I just love the horse butt strop.
Oh, and congratulations on 2 of your fine planes making it into the FWW Tools and Shops for 2013.

Regards
Les

**FenceFurniture** · 11th November 2013, 11:13 PM

Cracking good job that! I guess you could also bore some blind holes and glue some metal rod in - wooden caps for unattractive metal.

**derekcohen** · 11th November 2013, 11:23 PM

Thanks Les

I've only just received a copy of the magazine. I knew that FWW would publish the bridle plough (as they specifically asked for photos of that one) but they also showed an interest in a few others.

Regards from Perth

Derek

**derekcohen** · 11th November 2013, 11:25 PM

Hi Brett

It would be interesting to see what one could do with steel rod. I am not sure whether it would weaken the structure.

Try it and see

Regards from Perth

Derek

**FenceFurniture** · 12th November 2013, 07:56 AM

I was wondering about that myself Derek, but apart from interrupting the grain, the glued in metal would provide support to the structure, so maybe it would be okay. As you say, try it and see - I need to make a mallet.

**IanW** · 12th November 2013, 10:19 PM

Cor, you really like to whack 'em Derek! My 'ideal' mallet for lighter chopping comes in at about 600g, which in your archaic averdupois units equals about 21 ounces. If I really want to thump something, I use a larger mallet that weighs about 750g, or ~27 ounces. I think I need to get to the gym more.

According to my dim memory of Physics101, the kinetic energy, which is a function of mass & velocity, will be transferred to the object it strikes at a rate more determined by the deformability of the head material than its physical size. A wooden hammer head will take longer to transfer its energy to the chisel head after contact compared with a steel one of equal mass (but smaller size) travelling at the same velocity. Thus the steel hammer gives a 'sharper' blow. I reckon many of our nice dense hardwoods are closer to steel than wimpy woods like the Beech favoured in countries that don't have the choices we have. In view of all that, I do question the leather faces, as it seems to me they are somewhat counter-productive in this application?

I would say from my own experience that a smaller head makes it easier to strike accurately, too, so there is certainly merit in loading up a wooden head with metal to increase mass without increasing size, whether you do so as decoratively as Derek's or by hiding it as Brett suggests....

It is a pretty thing, Derek - pity you are going to go beating it up!

Cheers,

**jimbur** · 13th November 2013, 02:05 PM

I have two mallets both with redgum heads. I just weighed the larger one that is my favourite - two pounds exactly!
Within reason, I find a heavier mallet is easier to control than a lighter one. As BD is fond of saying, "Let gravity be your co-pilot".

**Sawdust Maker** · 13th November 2013, 04:00 PM

Nice looking mallet

reminds me of an article I read recently of a similar design laminated head with brass or lead inserts (might have been brass sinkers) to give added oomph

and congrats on the piccies of the tools in FWW as well

**Doggie** · 13th November 2013, 05:52 PM

Originally Posted by jimbur

"Let gravity be your co-pilot".

I admire the Ship's Engineering school of physical persuasion in these sorts of situations. "If you can't move it with a hammer, get a bigger hammer!" (And these guys were undoing nuts)

**enelef** · 13th November 2013, 07:14 PM

Nice Thumper Derek.

It looks great and does what you want.

**DSEL74** · 13th November 2013, 08:27 PM

You can bore holes in it and fill them with lead shot for more weight.

Is that * asterix shaped ting a scraper for the curves in the handle??

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