A New ‘Old’ Mallet from Woodworker’s Edge

It’s only fitting that a guy who reproduces antique furniture would, when he decides to dip his toe into woodworking hand-tool waters, choose to reproduce an antique tool. And so it is that today I announce the release of my first tool – a 16-ounce brass head mallet – designed for woodworkers.

Click here to go directly to the store.

A few years back while I was on staff at Popular Woodworking Magazine, I was bitten by the antique folding rules bug. As my collection grew ever so slowly, I considered reproducing rules. That idea didn’t get very far. Then one day as I sat in my cube tapping away at my computer Christopher Schwarz, former editor and now contributing editor, presented me with an antique brass mallet. He suggested that I reproduce it. I accepted his challenge, but only halfheartedly.

I played around with a SketchUp drawing of a mallet head, then sent it to my friend John Ostering at United Support Solutions so he could take a look and give me some pointers. Instead of evaluating the drawings, he put the team to work to make the very first prototype. It was awesome – and that swung me into full production mode. In my shop, I put the mallet to work so as to see what (if any) changes needed to be made. I came up with a few and when I visited John later in the year he handed me off to his lead guy and we worked the brass head into what it is today. Thanks John. Without your effort, this would have never happened.

With the new brass head in hand, I returned to work on an updated insert and handle design. Once complete, I produced a few new prototypes and asked fellow woodworkers to take a look and provide feedback. Feedback provided was excellent, and resulted in a better mallet. Now my mallet is ready to go. Tried and tested. I think you’ll find it exceptional.

Build Something Great!

Glen

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9 thoughts on “A New ‘Old’ Mallet from Woodworker’s Edge

  1. Glen, the mallet looks awesome. I cannot wait to get my grubby little hands on mine. In regards to my question from the other day will you be offering replacement white oak inserts (incase they become damaged).

    Good luck

    Joseph G. Coniglio

  2. Joe,

    I’ve been using my mallet for some time now and I have yet to inflict damage to the insert. For the time being, if you or anyone who purchases a mallet destroys the insert during ordinary use, I’ll send you a free replacement in exchange. Shipping is on me!

  3. Congratulations on a beautiful combination of form and function! I am hooked on your new blog and I can’t wait to see what other tools come from the Woodworkers Edge. I hope to add one of these mallets to my collection very soon!

  4. Superb, what a blog it is! This blog presents useful data to us,
    keep it up.

  5. Awesome work. I’ve added one of these beauties to my wish list!

  6. Glen,
    Mine just arrived. What a cool mallet. The balance, “feel” and workmanship are superb. I immediately started tapping on things!

  7. Thanks, Amos. Glad it meets your expectations. I hope to hear from more woodworkers once theirs arrive. Now get into the shop and put that mallet to use.

    1. I used it all day today chopping dovetails in 8/4 ash. Works as good as it looks.

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