Rob Cosman's Mallet - Small
I prefer a carver’s style mallet for chisel work. With properly sharpened chisels a medium sized mallet does the job without excessive fatigue to the craftsman.
Mallets I owned had smooth lacquered handles that had to be held tightly to prevent them from slipping. A long day of chopping mortises or dovetails would leave my hand and wrist sore. My solution was to tape the handle with sports tape like a hockey stick. This allows me to use a relaxed grip with a lot less fatigue.
We have been making our mallets for more than ten years and have recently changed to a resin impregnated maple head, making it harder and heavier than the previous woods. I think you will be pleasantly surprised at how comfortable my mallet is over the course of a long day in the shop.
Resin impregnated Maple head.
The handle goes through the head, glued and held with two #12 by 1-1/2" coarse thread screws that straddle the joint line securing the head to the handle.
Handle shape and hockey grip tape make it comfortable to hold with a relaxed grip. We tape the handle for you.
Slight taper of the head improves the striking angle of the head.
There will always be a slight variation from mallet to mallet since we turn these by hand on the lathe.
Available in two sizes: Regular and Small.
Small mallet averages 350 grams, head is 2-1/2"diameter by 4" and overall length is 9-1/2"