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Our Shop Shop Short Finger grips will save your thumbs and keep the mallet head from spinning as it's shaped. Shaping the Mallet Head You'll want to put washers at each end between the mallet head and jig to create a snug fit and keep the head from binding as you turn it. Set Up. To use the jig, position the fence until the centerline of the jig is aligned with the centerline of the bit. As you can see in the photo above, an auxiliary fence clamped to the front of the table keeps the jig sliding straight and smooth on the router table. The last thing to do before shaping the head is to set the bit height. Start with a shallow cut and work up to a higher setting. A 4"-dia. circle drawn on the "large" end of the jig will let you know when you're done. "Turning" the Taper. With the jig away from the bit, turn on the router. Then slowly slide the jig across the bit, keeping the blank steady as you go. After the first pass you can rotate the blank slightly and make another pass across the bit. You'll repeat this step as you make your way around the blank. Then raise the bit slightly and repeat the process. Your goal here is to end up with an even, cone shape, like you see in the main photo. Once it's shaped, you can sand it smooth. fa FRONT SECTION VIEW fence OFFSET ▲ Bowl Bit. A bowl and tray bit will leave a smooth finish on the mallet head. For more information on this bit, refer to Sources on page 51. w'-dia 2 hole »& x 1'/2" woodscrew At first glance, the mallet head on page 26 looks like it was turned using a lathe. But you can do all the shaping on the router table, using a bowl bit (margin photo) and a shop-made jig, as shown in the photo above. Build the Jig. In the drawing below, you can see the jig is just a simple box. It allows you to guide the mallet head safely over the router bit. One side of the jig is slightly taller than the other, raising one end. This tilts the blank so that as the jig and blank pass over the bit, the mallet head is tapered. The mallet head is held in place with two short pieces of dowel rod. NOTE: JIG MADE FROM PLYWOOD 24 ShopNotes No. 95 |
