HO Studley

Working The Infill Mallet Head Shell Casting

I’ve been working on the first set of Studleyesque infill mallet head shell castings from Bill Martley, getting an idea about how to get these from rough castings to finished tools comparable to the mallet ol’ Henry had.  That is, of course, my favorite tool in the tool cabinet.  Even though these castings are not the alloy I want to end with, this gunmetal bronze is simply a little too red for my needs, getting these prototypes to “finished” is a critical step in the creating mallets for sale.

I need to learn how, and how long, it will take for me to get from rough casting >>>> ready-to-sell, since that will determine the price for a finished item.  I can pretty much promise it will not be competitive with Harbor Freight mallets, or even Crucible Tools.  The$e mallet$ would be $everal multiple$ more pricey.  And, if there is zero market for them, well, I will have quite an inventory of expensive gifts.

One of the most important aspects of the process is getting the cove detail just right on the handle collars and around the faces.  Since I have a collection of chainsaw files of varying sizes I was able to find just the right tool for that task.  I just lay the round chisel in the groove of the cove and gently move it along the groove, making sure to not rock the tool in use.  That way I can get a clean, crisp surface.

The next step will be to establish the surface texture.  Stay tuned.