Rob Cosman's Mallet - Regular
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.
Early 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 heads.
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.
Regular mallet averages 450 grams, head is 2-3/4" diameter by 4" , overall length is 9-1/2".
My reason for a lighter than typical mallet head is covered in my tool mantra, "The sharper the tool the less effort is required to make it cut. The less effort (force) you have to apply to the tool affords you greater control: which is the end."