01/09/2022
I recently spent some time looking through FB Marketplace, searching for woodworking hand tools and found quite a few listings for what are described as "fine custom mallets". However, after looking at the pictures, it seems the idea and history behind the chisel mallet has been lost. So I thought I would help re-introduce this useful tool.
Once upon a time (think post-Revolutionary War to Great Depression era), a "wood wright" travelled from town to town, building or repairing furniture to eak out a living. As you can imagine, it would have been impossible to carry the load of tools we use today. He would have had a simple kit, consisting of a couple of types of saws, files, a "turn screw" (screwdriver), pencils, a marking knife, try squares, chisels, sharpening stone and a mallet. A simple kit to be sure, but also light enough to be carried by hand for miles between towns.
However, for today, the intent is to zoom in on the mallet. It was a simple design, made to easily break down to conserve space in the tool box. The chisel mallet had several features that made it such a useful tool. These features evolved from experienced craftsmen, through years of use.
1. Dense, hardwood:
Repeated blows will cause "dimpling". Harder woods like hickory, pecan or white oak will resist this. I personally prefer white oak barn timbers because the wood is stabilized after years of heat, cold, humidity, expansion and contraction.
2. Simple construction:
Mallets should never consist of more than two components (pieces or parts). One component for the head, one for the handle. I've seen quite a few head components that are laminated (glued) or "drilled & filled" (to add weight). While the idea is sound, the medium is still wood. Wood ages and non-stabilized wood expands/contracts. This weakens laminations, creating hazardous tools.
3. Angled faces:
There is usually a 7 to 10 degree angle cut from each face. This allows for use in tighter places without sacrificing usability. It also helps to ensure that force is adequately transferred from the mallet to the chisel, regardless of the angle. It is much simpler to achieve a correct strike to the end of a chisel with the larger, angled faces of a mallet than with the smaller face of a traditional hammer.
Now there's nothing wrong with the fancier, laminated mallet heads consisting of multiple species to stand out. However, the differences in wood density leads to uneven wear to the faces, limiting the overall life of the tool. They look great on a shelf though! Other designs that mimic a dead blow mallet can have unpredictable results, especially in changing environments. Here are some great videos available on YouTube worth checking out if you want to learn to make them.
Paul Sellers:
Part 1: https://youtu.be/u31Ixu6mSHY
Part 2: https://youtu.be/UeOtTkW9oJw
Part 3: https://youtu.be/rC3AskwKOiY
