I'm about to make a joiner's mallet and I'm considering making it a dead blow type. Is there any significant reason not to build it this way, besides the possibility that it might be overkill or more complex than necessary?
3 Answers
There's really no downside to making a dead blow mallet if that's what you want. Traditional mallets have worked for centuries without issues, but a dead blow won't cause any harm unless it bursts open like a piñata! Just keep an eye on the construction to make sure everything's secure.
I just made a dead blow mallet using layered plywood and filled it with steel shot. It’s pretty fun! Just be aware that the shot can create a lot of force, which can cause issues if it breaks open. I had to reinforce my mallet after it burst, so think about your design carefully. If all goes well, I might cover it with some sturdy plastic for extra durability.
I recommend making two mallets! A dead blow is great for tapping pieces together without needing a lot of force, but remember it can get heavy after a while, which might tire you out. Plus, for chisel work, you might want a lighter, standard mallet instead.
That's super helpful! I'm thinking of using a solid block with some thinner pieces glued on. Maybe going for a smaller cavity might help manage that burst risk.