Making A New Mallet

I have been experimenting with a new mallet idea. The idea is to glue up a mallet from smaller pieces of wood and then carve that glue up on the rotary 4th axis on the CNC. I started by making a prototype out of Sequoia wood mostly to go through the process: from first making the glue up, to next making a model in the computer, and finally cutting the final shape. I then made 3 versions of a newer design that were closer to what I would like as a mallet. One of these mallets is made completely of fir. Another mallet has a maple handle with a tropical hardwood head. The third one has a fir handle with a tropical hardwood head. In this third mallet, I put weights within the head. I like the weight of this third mallet. It is the one that most feels like it could do its job.
Tools used in this project can be found at www.frankmakes.com/
Rotary Axis: www.cncrouterparts.com/pro-cnc-rotary-axis-p-724.html
Fusion 360: www.autodesk.com/products/fusion-360/
Aspire: www.vectric.com/products/aspire
To see upcoming projects follow me on social media
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[@jon_raymond]

PSA - If you like Frank's content and want to support him there is a link to his Patreon in the video description.

[@Jer_Schmidt]

I like the way you locked the head pieces to the handle. Looks nice and should work well.

[@chefdan87]

Creators like yourself are the reason i stopped watching television. Tv has continued to degrade into divisive politics, untrustworthy "news", and garbage reality shows. Thank you for your hard work and dedication to your craft and bringing us along with you. I always look forward to see your new uploads.

[@OlivierVerdier]

Great project and film idea - Thanks Olivier

[@markgoode4109]

Super video and lovely mallets. I'm sure all three will be a pleasure to use around the shop. Thanks for sharing your ideas and obvious skills. Best wishes.

[@denishuber7758]

i can remember when i was studying carpentry back in the day...we also had cnc programming....back than ( about 1997) it was pretty much writing the tool passes and simulate it...other words a pain in the ass..... but now i see.. you just sketch it and it autotransforms into the right code.... im so stunned right now.....and that lathe attachment....unbeliavble..... i really wanna see more...keep it up !

[@xyzcreate]

I love how you explain the thought process behind every decision you made on the mallet (and all your pieces for that matter)

[@paulolange3462]

I really love your content, the best KZbinr IMHO. You're just an amazing artist.

[@LonghornWorkshop]

Frank you are always pushing the envelope of creativity and I love that.

[@keschln]

Once again a beautiful project! I love the time lapse of the final pass of the CNC over the mallet. It looks as if the mallet was always inside the blocks of wood and it is just shedding its skin. Very cool!

[@shimmeister1062]

The video of the finishing pass on the CNC is hypnotic - I could watch that for ages.

[@randyallaway4085]

Nathan! That guy is a lifesaver.

[@gabriellplplp]

Thank you Frank for making this videos. I'm passing for a hard time in my life in this last 3 months, and your videos make me calm down a little bit and enjoy life a little bit more. I know that i'm not the only one here that has difficulties in life, so, you help not only me, but a lot of people with your videos. Thanks again. Big hug from a brazilian fan

[@TheImpiroGirl]

Wonderful to see this process, those time lapses of the mallets being carved were so cool!

[@mlubecke]

This is totally awesome! You have Mastered wood working..

[@LeviShores]

As always, thank you for sharing these experiences in such a beautifully produced way!

[@IAmKyleBrown]

I could watch this cnc turning all day... So I will! Looks great Frank!

[@TimPiggott]

Wonderful use of modern tools. Thanks for inspiring us xxx

[@SmallWorkshopGuy]

Frank, you have the best toys and I love watching you use them. You also produce the most artful videos of anyone with all of your camera and editing techniques. Please continue doing them for your dedicated fan base. Watching you use your toys is satisfying for us but a whole lot less expensive than trying to duplicate your equipment and genius knowledge!

[@hebierob]

Super nice Frank! So precise!

[@guyward5137]

I haven’t seen your videos in awhile but sure enjoyed watching you make a project again. Thanks for sharing. GW

[@Baureo]

Man, I love your little chuckles and you trying stuff on camera without knowing for sure how it will turn out.

[@christofix]

It is so cool to see that cnc make the mallet. I'm always amazed when i see what these machines can do! Awsome video my friend!

[@Toms_Wood_and_Leather]

Since you were having trouble with the handle; I wounded if it would have been easier to prototype the handle for thickness and shape on the lathe then transfer those measurements into your CAD.

[@davidmarshall2399]

Tom’s Wood and Leather could probably put an edge finder in the cnc and pick it up directly.

[@DavesShed]

Your videos are always so entertaining. Even when you are prototyping a mallet on a CNC.

[@handcraftpassion7845]

love your workbench, love your tools, love your work!

[@thomasutley]

Nice process, Frank, and a great showcase of blending multiple tools and software. One approach for v3 would be to replace the mass of the ball bearings with an equivalent mass of lead shot. You’ll find it dampens better and makes a more pleasing sound. Beautiful job!

[@anthonyreid9832]

Nice work. I am really liking the lathe addition

[@BruceAUlrich]

Some interesting experiments. I enjoyed walking through that with you.

[@riizm]

I really love that your videos have evolved over the years. You have always had really great videos of course. I think there are maybe two or three different types of Frank videos. I love this kind where you go into detail about the equipment and process. The short skirts and whatnot are always good too. Don't think there's ever been a bad Frank Howarth upload.

[@danvalleskey]

You have moved beyond anyplace I will ever go. Good job.

[@dworkeen]

This a truly wonderful video that integrates a deep understanding of the materials, the way they can be worked and the way that modern tech can help a project. This combination of old school understanding of the materials used with an equally deep understanding of todays processes is a delight to see. Love it

[@kobiekaasjager4822]

Frank you are amazing full of surprises.

[@andrewevans7184]

Happy Fathers Day Frank and thanks for another great 18:29 min of vicarious creative mastery .

[@johnc4774]

As always, wonderful. Your the reason KZbin exists.

[@cryptojunkie5875]

Nice job Frank. Great to see the new 4th axis being used.

[@nephimitchell]

One of the coolest time lapses I've seen in a while.

[@Sludgepump]

I love that way that you always consider form and function, Frank. Fantastic mallets... Looking forward to the amalgamation of the three prototypes in mallet #4.

[@sffpv9671]

Mesmerizing to watch the CNC at work. They all look beautiful to me. thanks for sharing

[@stephenlee62]

Frank, I appreciate your "to camera", where you talk directly to the camera. I understand that you have challenges with a stutter, and that makes even more special when you speak directly to "to camera". Do more of it. It is appreciated.

[@TheLatestChance]

Hi Frank. Great video, as always. What if you put a spring inside the void to push the ball bearings against the outside of the head? It would also have the damping effect, but without the rattling noise.

[@joshuablair6120]

This method would partially work to mitigate the rattling. However, springs can't adjust for the force being used to swing the hammer. It might dampen the rattling on a medium swinging of the hammer, but if you double that swinging effort, the spring will be using the same rebound on both types of swings, and you'll still have rattling. This is one of the reasons why dead blow hammers don't use large 1 inch bearings. They used smaller shot for a number of reasons, but smaller shot will also lessen the sound. It's like putting a single stone in the head of the hammer, or using sand instead. The rock will be loud, and the sand will be soft.

[@etwoodworks]

How about the bearings in a void filled with Epoxy or something? Should be solid inside to avoid any rattling.

[@michaelposey6529]

Fill the void 3/4 full of iron filings or steel filings with a bit of oil in there. Sand sound with ball bearing weight.

[@nutsmcflurry3737]

Hard steel shot and it would be a true dead blow hammer.

[@HBSuccess]

@@etwoodworks That space is what makes it a deadblow mallet. The moving mass of the load counteracts/cancels the recoil of the tool because it arrives at the face a millisecond or two after the strike. Big ball bearings aren't going to be effective though regardless - they're going to add resonance instead of cancelling it. He needs something much more granular.

[@walterperrault]

Great video Frank can't wait for the final version of the mallet

[@artofmana]

Please do keep making these! I love watching your process for iterating designs and landing on the best. Also, congratulations on some neat new tools! You do a fantastic job and are one of my favorite KZbinrs!

[@fatdriver]

Very nice work as always! The woodworking and your video work! I really do enjoy seeing how the mallet evolved from start to finish. It's more the just a blunt tool!

[@gdfannola2086]

Frank I love watching your videos

[@petermarsh4993]

Dear Frank, nice product. Fascinating construction method using CNC. I can only dream to own such a device. For now it’s handsaws, chisels and a lot of sweat.

[@jakobkarlqvist5264]

I have now watched all of you vids, including all of the very first ones back in 2012. Don’t regret anything ;) :)

[@TM-zp1jh]

Frank thanks for all the great content. I am glad you backed off at 0:53 from that table saw cut. To anyone without a lot of table saw experience, had Frank kept pushing through, this would have been a very different video ending in some nasty kick back. When that board started walking up, it probably wasn't very far from being a disaster. I wish that would have been stressed more during the video. We always think about cutting off a digit, but kick back can do some nasty damage. Always use a splitter, and hold downs aren't a bad safety measure either.

[@SolveFixBuild]

I love everything in this video. Never wanted to make a mallet, now I do!

[@thedistractedmaker]

Looks great Frank! I agree with the extra wiggle with the bearing. Makes it more like a dead blow hammer. You don't want to fill it up 100% with shot.

[@ARCWoodCraft]

OMG, whether your on the lathe, the cnc, workshop tour or anything else, your videos are totally engrossing 👍👍👍

[@prlswabbie]

The irony of needing a mallet to build your new mallet, i love it!

[@FarbulousCreations]

Oh man, I've been dying to see you have a rotational axis at your disposal for CNC work. Can't wait to see what else you do with it!

[@rexg1960]

Thx Frank it's always fun to watch you create!!!

[@billqqq]

Hmmmm - I need a new mallet, and I don't have a CNC.... and it's Father's Day! "Hey honey!..." Thanks, Frank!! :) (And Happy Father's Day to you, too!) Great video, as usual. Nice stop motion on that final pass...

[@HBSuccess]

The space in a deadblow mallet is what allows that mass to counteract the recoil. Without the ability to move, all you have is a heavier mallet. When I was a kid I tore apart a deadblow mallet in our shop just to see how it worked. it was packed to approx. 3/4 of the available space with tiny steel ball bearings (smaller than buck shot). That thing was *very* effective - when you hit something with it, it felt almost like an external force was sucking it on to the surface of the work. Of course my father tanned my hide for destroying it - but we had several of the same model in the shop LOL.

[@heru-deshet359]

Your shop has me green with envy.

[@TheBearDenPhotography]

As always, amazing work! Happy Father's Day Frank!

[@Sadowsky46]

Wow! The most complex procedure to make a mallet I ever saw (saw?😉). Amazing!

[@sapelesteve]

Awesome video as always Frank! Love how those all turned out. When you finally perfect the final design, I would love to purchase one....................... :)

[@xinixxagnix201]

Blessed with those machines xD Great Job Frank!

[@guitarchitectural]

Awesome work! Makes me really want a CNC! I'm with you on the weighted head - my mallet is full of lead shot and it's really good to dampen vibration but it also increases the strike force (or it feels like it does anyway). I would suggest trying smaller ball bearings for a nicer sound than the clack of the 1" ones.

[@joebanks548]

Wow Frank. I was putting off watching this video because I thought "how interesting can a mallet video be". Turns out very interesting. I love your camera work on this and that finish pass on the CNC is some sweet machinist porn. Thanks so much for making these videos.

[@jonikuhn2441]

Love the "sawing-face" at 0:52 , I don't have any mirrors in my shop but I bet that's exactly the way I look when I use the tablesaw.

[@patrik5123]

5:44 that's SERIOUSLY satisfying to watch.

[@al1843]

Frank - your “prototype” is better than anything I could do, even if I had a CNC! Awesome video as always.

[@Harko-]

Very interesting use of the 4th axis and with a nice result.

[@fynbo1007]

Very beautiful design, thank you for sharing your amazing video. God bless you and your family

[@derekpeterson8005]

Very cool! I love your content, thank you for sharing your time and talent!

[@wolverjay]

Greetings from Ireland Frank love your work and your channel.

[@paulcookcook1500]

Frank... They all look fantastic

[@SamuraiPipotchi]

One thing you could give a go for dampening is to try putting a slightly tense spring in between two ball bearings instead of having three loose ball bearings in the head. I'm not sure how well it would work, but it could be an interesting experiment.

[@sugarbooty]

I think it might bounce back if you did that, interesting idea

[@larscw74]

Really cool to see the whole design process. It might be an idea to go for an oval shape for the handle as that you fit better in your hand

[@jmklamm]

Thanks Frank- happy Father’s Day!

[@Wingman4l7]

Frank, you're a national treasure. :)

[@billiondollardan]

I love Frank's videos. I feel like KZbin NEVER tells me when they're published. I made sure to hit the bell today. I hope I get more notifications now

[@paulatapogna9093]

Amazing as always. Hypnotizing time lapse work.

[@joestallings6993]

I like the idea of a wooden dead blow mallet. I'm wondering if one ball hammering in the same small spot on the inside of the head will eventually do some damage. They're usually full of shot, rather than one (or two) big bearings. Interesting video!

[@andrewb9590]

2:00 me - aaaanndd done. 6:32 Frank - so now we have a prototype.

[@uknowulikethat4042]

damn it Frank, all I can think of now is "it's hammer time" :)

[@banditgo9204]

Yeah buddy your real Craftsman and artist nice machine

[@jasonharrelson83]

Frank,.. you should be an architect or engineer. Oh, nevermind. You have given me so much to think about! I've never really considered a 4th axis in woodworking. I guess now I'll consider how lumber will be and react in alternative dimensions lol

[@marcdavenport6987]

I really enjoy all the problem solving commentary that goes into your videos. It the real valuable content. I am surprised your radial arm saw gave you those results. I wonder what is going on with that saw. I know you have a thing for radial arm saws. Maybe there is a saw tuning video in the future.

[@marcdavenport6987]

Also, how do you make a video about a mallet and not hit anything?

[@rodriguez8246]

Coolest guy on youtube. That new cnc set up Rocks!!!

[@Dont_Poke_The_Bear]

That's cool process and a great video! I hope you drop some for sale! Happy Father's Day Frank!

[@youtubeguest6177]

Happy Father’s Day, Frank!

[@ThisIsHowIMadeIt]

Hey Frank, when you go to fourth axis, where is your starting point in aspire? How do you know where the fourth axis zero is? Is it just Top Front Corner like before? Are are you using the center line of the rotary? Not sure I’m making sense...???

[@Soggstermainia]

I would add some 1 inch round discs of leather to the ends of the holes you drilled before adding the ball bearings, help reduce the noise but also improve the damping effect too :-)

[@MRrwmac]

Amazing work using the CNC! Glad you got the design you wanted and a few extra (just in case one breaks- haha).

[@agustinriberaberenguer9859]

Desde España un aplauso al maestro..........espero mas videos

[@ianstradian]

Hey frank, try using lead pellets ( birdshot from a shot gun shell number 6 or 7 should do great you can buy them from any reloading website. )in the head of the handle, you may need to seal the inside cavity so no moisture gets in and causes the lead to eventually begin to clot up, but the hammer will not rattle and still give you that dead blow effect. You can measure the weight of the head more precisely also by using lead pellets.

[@minutemark]

That 4th axis is really sweet!

[@danielwadeson5307]

Please never stop doing that random chuckle after a sentence 😝

[@alanpeck6214]

Great video, interesting to see and hear

[@SanAndFe]

Great photography and content as always Frank. Now where have we heard that before, ones too hard, ones too soft and ones just right, well almost. I see future bowls being made on the latest addition to the CNC. 👍🏻

[@michaeldavies9186]

Excellent video. Unsurprisingly, they turned out to be very nice. With regards to the ratios used (head to handle, head dimensions...), in the future it might be worth considering the golden ratio.

[@willierants5880]

0:03 Dang it Frank!!!! You've got to stop popping in on us like that!

[@rodriquh]

Great video as always Frank. I'm just drooling over the new setup, how cool is that 4th Axis? The mallets look great, but I'm sure you're going to dial them in and save that file! Thanks

[@michelevitarelli]

Great project and video. Thanks for sharing.

[@roybailey9554]

Very very nice work 👏 👏👏👏👏👏