Play Time – Infill Mallet 2

With the two halves of the mallet head shell soldered together I got to work making it into something resembling what I wanted (a la Studley’s mallet).

I began by trimming off the overhang from the soldering with the band saw.   One of the great things about working in brass, bronze, copper, and aluminum is that they can be worked with a variety of woodworking hand tools and virtually all woodworking power tools and machines.  Well, maybe not jointer and planer.

Once the trimming was done I cleaned and squared the head on the stationary belt sander.

Then, while everything was still square I drilled then filed the holes in the center of the top and bottom faces.  These holes allow for the handle to protrude all the way through the metal shell and the wood block infill.  Doing all this before shaping the head was the only way to get it right.

Up next – on to shaping the head.