Monday, April 30, 2012


Noble Ignitus Extreme Croquet Mallets: 
a few photos to show the process of hanging (attaching to the helve) the mallet head.

a 11 3/4" fishtail oak mallet head
I prepared the mortise by first boring out the main cavity.

A detail of the boring.

The cavity gives access to hand rasp the mortise walls. Only rasping by hand allows me to make the small adjustments needed to best mirror the tenon. A tight fit will make a perfect wood joint.

The bottom of the mortise is a bit wider than the top. This will allow the tenon to spread when I drive the wedge into it. 

The hand rasping also has the benefit of leaving little tooth marks. These very small grooves will increase the surface area of gluing contact and thereby creating a stronger bond.

Each mortise and tenon joint is a bit different. It all depends on the tenon shape and the grain of the wood being used for the mallet. 

I do not even worry about how many times I dry fit the joint before I am finished. I can say it is a lot!

A perfect fit.

I only use high quality waterproof glue. I apply the glue to the inside of the mortise, the outside of the tenon and on the wedge itself. 

The wedge is made of a softer wood and when wetted (with glue) is softened up a bit more. This will allow the wedge to really form fit into the tenon.

This mallet is ready for final sanding and then for some flash.

As the pictures demonstrate, there is NO way this head can come off the helve. The mallet is both mortised and tenon secure with the addition of waterproof glue. 

Thank you,

Saturday, April 28, 2012


I actually use an old copper & brass gillette safety razor and i have three boys. this is the image of nightmares!!


Was thinking about the profile question of favorite books and of course thought of this. First all grain beer recipe. then my thoughts turned to details and i remember the brew session being notable because it was in the winter and we didn't have a wort chiller. we took the brew kettle out side and packed snow around it. it took hours for the damn pot to cool down. it took another two months to put the money together for copper tubing and fittings for a proper wort chiller. it was a good beer.

Friday, April 27, 2012


Ready to launch "Thought Rockets". these will carry a thank you and contact information. next to fuel with other notions.

Thursday, April 26, 2012


First batch of extreme croquet mallets ready for the etsy shop that doesn't quite exist yet.