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Joefish
05-20-2006, 09:02 AM
I got a good deal on some hammer handles

http://www.metalmeet.com/photopost/data/500/medium/P5180001.JPG

Here is my question. How do you make this hole this shape and be tight fit?

http://www.metalmeet.com/photopost/data/500/medium/P5180002.JPG

sorry the photo is not clear but thats the shape . I got a load of maple firewood and thought I might try makeing some slapers and hammers if I can do this.

Thanks in advance .

anders nørgaard
05-20-2006, 11:40 AM
Hey Joe,

Nice find http://www.metalmeet.com/forum/images/icons/icon7.gif
Unless you have a CNC router that can do the trick for you http://www.metalmeet.com/forum/images/icons/icon10.gif http://www.metalmeet.com/forum/images/icons/icon12.gif here's a way that worked for me.

Use a drill press and drill holes that are close to the size of the shaft. Use a wood chisel to remove the rest of the material and last, take one of those coarse files for woodworking (don't know what thy are called in English) http://www.metalmeet.com/forum/images/icons/icon10.gif :p
Finish the hole so that it tapers from both sides.

http://www.metalmeet.com/photopost/data/500/medium/Hammer_Shaft.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17320&size=big&cat=500&page=1)

Peter Miles
05-20-2006, 08:50 PM
take one of those coarse files for woodworking (don't know what thy are called in English)

Hi Anders,

That might be a wood rasp.

Peter

anders nørgaard
05-20-2006, 09:14 PM
Hi Anders,

That might be a wood rasp.

Peter

Hi Peter,
Thanks! Guess you're right.... anyway, that's what they are called in Denmark http://www.metalmeet.com/forum/images/icons/icon10.gif

rsanter
05-21-2006, 09:56 AM
I did it on a mill for the major material removal and then finished with a file. remember you have to have a back angle to the hole so the heat will not fly off of the handle

bob

kenb
05-21-2006, 06:54 PM
I got a good deal on some hammer handles
Here is my question. How do you make this hole this shape and be tight fit?
Thanks in advance .

Hi Joe,

When I made my baseball bat mallet, I used a dremel tool with a small drum sander attachment on it to carve out the tapered oval hole for the handle. I started by drilling a 3/4" hole through the bat, and then followed up with the dremel tool to carve the rest of the hole to shape. The results were excellent with a nice tight fit for the handle, and the job was done in less than 45 minutes.

Cheers,
Ken

Joefish
05-22-2006, 08:31 AM
Man this aint easy at least the way I have been trying it. At least the wood still is good for a fire.

Hay Bob
I dont get the " back angle"I guessing the hole has a taper. Larger on top than the bottem so the dead weges on the handle when the wedges are pounded in.

Hi Ken

I forgot about my dremel tool, I have tryed my die grinder and rotery file works better on metal than wood, so today Ill give that a try.

I hope I can do this. I really dont want to buy wood hammers because I am cheep oh,, I mean thrifty.

Hi Anders

You are very knowlageable, I dig the computer drawing some some of you guys do. Thanks for the input!

Joe Andrews
05-22-2006, 12:27 PM
Hey Joe,

There are so many different configurations on Handles, but not a clear definition on hopw to cut them. Anders Drawing is very similar to the way I've done them in the past. Below is a MSC's Handle page, they briefly describe the hole. A bit of a snug fit is what you want, then drive in the wedge.

p.s. I sent your 4x9 to Heat Treat today.

http://www1.mscdirect.com/HTM/2006/img/2313.gif

GTmike400
05-22-2006, 01:37 PM
Too bad you cant weld wood.

You might be able to use a Dremel to make that hole. Make sure it is a really snug fit, its not fun when the heads fly off.

rsanter
05-22-2006, 02:13 PM
Joe
you are 100% correct
you want the hole at the top to be just a but wider (not longer) so that when you put the wedge in the end of the handle to spread it the haed will be trapped and cannot fly off.

I dont like it when the head of my hammer flies off, but I can tell you the guy that gets hit by the hammer head likes it even less

bob

kenb
05-22-2006, 03:55 PM
I dont get the " back angle"I guessing the hole has a taper. Larger on top than the bottem so the dead weges on the handle when the wedges are pounded in.


Hi Joe,

See the image below for the close up details on a tapered hammer handle installation, as viewed from above looking down at the hammer. As you can see, the hole is usually tapered from both sides to trap the hammer head securely when the wedge is driven in.

Cheers,
Ken

http://www.metalmeet.com/photopost/data/3589/medium/hammer_head.jpg

Tony Sanchez
05-22-2006, 07:25 PM
---Joe, On all the wooden mallets that I make, I do what Richard suggested. I drill a blind hole, shape the handle to fit, place wedge in handle tip and bottom it out. I usually use some Gorilla glue, haven't had one come apart yet.
---Tony.

Tony Sanchez
05-22-2006, 08:07 PM
---Here are a couple of photos.
---Tony

http://www.metalmeet.com/photopost/data/3758/medium/mallet_01.jpg

http://www.metalmeet.com/photopost/data/3758/mallet_02.jpg

Boogiemanz1
05-22-2006, 08:45 PM
Nice....what is the specific purpose? Stretching aluminum?..................john

Tony Sanchez
05-22-2006, 10:32 PM
---John, I use them alot on aluminum, tipping edges, hammer forms, aligning edges when tack welding. They don't leave any hammer marks.
---Tony

Boogiemanz1
05-23-2006, 06:43 AM
They sure look nice...............john

gator 1
05-23-2006, 06:59 AM
Are you sure you made these, All the screw heads are going in the same direction. I thought Dan Shady was the only one that precise...:lol: :lol: :lol: ...Gator

anders nørgaard
05-23-2006, 07:42 AM
Are you sure you made these, All the screw heads are going in the same direction. I thought Dan Shady was the only one that precise...:lol: :lol: :lol: ...Gator

No he's not! That's the reason why I use TORX screws :lol: :lol: :lol:

Joefish
05-23-2006, 08:34 AM
You guys are the best! Again lots of good answers, one of my favorite sayings is" no one knows more than all of us "

Hi Tony

That is a really nice hammer! Looks Perfect!

I like to keep it simple and easy so I will try to get it close shape the handle a little and put it together with glue. :-D

It will be a while but I will put pics of what I came up with.

hodijag
05-23-2006, 12:53 PM
Hi Joe,

Thanks for raising the subject of wooden hammers.
I am starting to realise that instead of a lot of machinery, I am seriously short on hand tools at the moment so I said to myself a wooden hammer might come in handy.
Since it was raining over here I told my wife I could not continue working on the garden terasses anyway, so I managed to spend an hour in the workshop.

Here it goes:

The stuff I had lying around:

http://www.metalmeet.com/photopost/data/500/medium/hammer_001.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17365&size=big&cat=500&page=2)

Don't ask me the type of wood, it came out of the house when I tore down the living room. I bought the handle though.

Cutting to approximate size:

http://www.metalmeet.com/photopost/data/500/medium/hammer_002.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17366&size=big&cat=500&page=2)

Taking the largest drill I could dig up in 5 minutes

http://www.metalmeet.com/photopost/data/500/medium/hammer_003.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17367&size=big&cat=500&page=2)

Drilling first hole:

http://www.metalmeet.com/photopost/data/500/medium/hammer_004.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17368&size=big&cat=500&page=2)


Measuring up the width of the shaft:

http://www.metalmeet.com/photopost/data/500/medium/hammer_005.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17369&size=big&cat=500&page=2)

Drilling 2nd hole, trying hard to stay parallel to the firts hole:

http://www.metalmeet.com/photopost/data/500/medium/hammer_006.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17370&size=big&cat=500&page=2)

Chiseling out the wood between the two holes:

http://www.metalmeet.com/photopost/data/500/medium/hammer_007.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17371&size=big&cat=500&page=2)

and

http://www.metalmeet.com/photopost/data/500/medium/hammer_009.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17372&size=big&cat=500&page=2)


Cleaning up the hole with a wood file:


http://www.metalmeet.com/photopost/data/500/medium/hammer_010.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17373&size=big&cat=500&page=2)


Sizing the shaft width to fit the holes:

http://www.metalmeet.com/photopost/data/500/medium/hammer_011.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17374&size=big&cat=500&page=2)

Don't worry, plenty of material left here, just picture misformation.

Cleaning up the cuts:

http://www.metalmeet.com/photopost/data/500/medium/hammer_012.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17375&size=big&cat=500&page=2)


With a bit of filing on the shaft to finetune, inserting with some glue:

http://www.metalmeet.com/photopost/data/500/medium/hammer_013.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17376&size=big&cat=500&page=2)

Starting to look like a hammer now.

Getting into shape:

http://www.metalmeet.com/photopost/data/500/medium/hammer_014.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17377&size=big&cat=500&page=2)


http://www.metalmeet.com/photopost/data/500/medium/hammer_015.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17378&size=big&cat=500&page=2)


And finding I didn't like the balance, so I cut off a slice on the front.

http://www.metalmeet.com/photopost/data/500/medium/hammer_016.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17379&size=big&cat=500&page=2)


Reshaping:

http://www.metalmeet.com/photopost/data/500/medium/hammer_017.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17380&size=big&cat=500&page=2)


And finished shaping and sanding:

http://www.metalmeet.com/photopost/data/500/medium/hammer_019.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17381&size=big&cat=500&page=2)


While putting on a layer of polyurethane, I thought of some unidirectional carbon fiber I had lying around so I threw it in to keep the head from splitting.

I also did not like the idea of a wedge because it would tend to split the head so I cross drilled and put a bolt inside to hold everyting together.

http://www.metalmeet.com/photopost/data/500/medium/hammer_023.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17384&size=big&cat=500&page=2)

http://www.metalmeet.com/photopost/data/500/medium/hammer_021.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17382&size=big&cat=500&page=2)

And this is the result.
I hope I will be able to scare the metal into shape now when it sees me coming with this thing.


http://www.metalmeet.com/photopost/data/500/medium/hammer_022.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17383&size=big&cat=500&page=2)


Hope this helps you along.

I'm glad I spent an hour to get me a new toy to test next time I'm in my workshop.

I like your post dolly. I am also putting one together and will post some pictures when I'm done.

Kind regards,

Marc.

Joefish
05-23-2006, 05:10 PM
Hi Marc

Thank you for a great" HOW TO MAKE A WOOD HAMMER 101, I managed to get one handle glued in to a hunk of wood today,

Thanks for the nice comment on the beater stand I saw one like it in someones photo gallery sorry I dont remember so I could give credit.

tdoty
05-23-2006, 05:25 PM
Hey Joe, did it look like this:

http://www.metalmeet.com/photopost/data/3097/48hammerstand3.jpg

That's the one I "copied" :-D The one in the pic was built by John "Nortonscustom" Norton.

Nice work!

Thanks for the How-To Marc!

Tim D.

Tony Sanchez
05-23-2006, 09:39 PM
---Here are some of the mallets and slappers that I am presently using, including my Bugly slapper.
---Tony

http://www.metalmeet.com/photopost/data/3758/medium/tools_in_use_02.jpg

http://www.metalmeet.com/photopost/data/3758/medium/tools_in_use_05.jpg

Joefish
05-23-2006, 10:02 PM
Hey Joe, did it look like this:

http://www.metalmeet.com/photopost/data/3097/48hammerstand3.jpg

That's the one I "copied" :-D The one in the pic was built by John "Nortonscustom" Norton.

Nice work!

Thanks for the How-To Marc!

Tim D.

Hi Tim

Yea thats it! I finished my post dolly I was inspired by one I saw for sale. both units were changed form the orginal due to the choice of materals was limited to what I had on hand.

hodijag
05-24-2006, 01:32 PM
It is still raining over here so I continued building up my hammer collection.
I replaced the chiseling with a bit of milling and turning, and this came out:

http://www.metalmeet.com/photopost/data/500/medium/hammer_026.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17396&size=big&cat=500&page=1)

I ran out of large diameter delrin for the little head so it is a bit ridiiculous as it is now, but I'll make a correct dia one when I find some more delrin on ebay.

http://www.metalmeet.com/photopost/data/500/medium/hammer_027.jpg (http://www.metalmeet.com/photopost/showphoto.php?photo=17397&size=big&cat=500&page=1)


Kind regards,

Marc

Gene_Olson
05-24-2006, 02:23 PM
Marc,
There is no "correct" dia.
Only the one that works for you on the job you are doing.
That small one will be great for some things.

WE all have favorites, but that goes with personal styles and there are lots of ways to the same end.


G.

Joefish
05-24-2006, 05:56 PM
Here is what I got done today

http://www.metalmeet.com/photopost/data/500/medium/P5220017.JPG

I got the hole close and glued it up

http://www.metalmeet.com/photopost/data/500/P5220014.JPG

got the plan layed out

http://www.metalmeet.com/photopost/data/500/P5220015.JPG

some time on the shaper brings it allong quickley

http://www.metalmeet.com/photopost/data/500/P5220016.JPG

more shapeing I like the new sander notice all those darn gards are out of the way

http://www.metalmeet.com/photopost/data/500/P5220028.JPG

well ther are my first two hammers I think I will drill a hole and glue in a wood dowell just to make shure the head stays in place.

Thanks again for the info. :-D