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I have been saving a large hunk of copper round stock for a very long time, and I finally found a use for part of it. The top ring is a ½” thick, and the bottom ring is ¼” thick. I had Marv make these ½” smaller in diameter than the leather would be. The thickness provides the mass for the mallet. It would be too light without these. I also had Marv make an arbor for me to turn the leather discs into the cone shape I wanted. The arbor allowed me to glue the discs together so I would not get them mixed up when I put them onto the metal shaft. It also allowed me to compress the leather.
Here the assembled cone has been turned, and it is still mounted on the arbor. I used a very sharp scraper to turn the outside. The tool above it is an antique washer cutter that I have had for a long time, and this is the first time I have ever used it. It is a wonderful tool.
Here the washer stack has been installed onto the metal parts, and it is waiting for me to make a handle for it.
Here is the handle stock. Teak for me, and purple heart for Marv. He will most likely just display his, whereas I will actually be using mine.
And here they are in all their radiant beauty. I used only wax for a finish. I do not like film finishes on my handles. You will notice that I decorated the handle on Marv’s mallet. Mine was left plain. This project was a lot of fun to make, but I can’t recommend it to anyone else simply because of the amount of skills and tools required. I am certain that a simpler mallet can be made, and that I can heartily recommend. I have been wanting this mallet for a long time, and now I finally have one. Jim
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