Shenandoah Awls

Previously I've written about the business I operate with Jeff Fleisher, called Shenandoah Tool Works, and the woodworker's mallets we introduced in 2013.  We since have added a new product, which we call the Shenandoah Awl.

Tiger Maple Awl

The Shenandoah Awl is a birdcage awl that incorporates a unique design for the handle, a large round bulb shape that allows the user to easily apply plenty of torque in use.  In addition, the steel shafts, made of oil-hardened (O1) steel, are shaped in a twist that gives them a decorative touch.  The shafts are hand-forged by a local blacksmith.  As with the Shenandoah Mallets, the handles are hand-turned from a variety of domestic and exotic hardwoods, the most popular of which are those made with crotch walnut and tiger maple.

Birdcage awls differ from scratch awls, which are intended to mark lines in wood.  Birdcage awls have a square shaft that, when twisted in the wood, is capable of drilling holes to start screws, install locks, or simply to mark the location to start a drill bit.

The awls have been selling very well and have received good reviews from other woodworkers, including Popular Woodworking magazine.  They are available at the Shenandoah Tool Works website and are priced at $54.99 USD.

Norm

Making a Mallet

I had been making jigs to use in woodworking and decided what I really wanted to do was to make something "real." I remembered a simple band saw project in Mark Duginske's Band Saw Book for a wooden mallet. Knowing that I will soon be using my chisels to clean out mortises and the like, I decided a mallet would be a good next project.

I started with some rough soft maple and walnut and jointed and planed them smooth. Then I cut the maple into three short pieces and glued them together in a stack. This became the stock for the head of the mallet. While this was drying, I cut the handle from a larger piece of walnut. I cut the tenon on the walnut on the band saw with no difficulty. Then I cut the handle to shape to fit my hand and ran the whole piece through the router table using a roundover bit to ease the edges.

When the glue had dried on the maple, I cut the stack to final shape on the band saw. Then, I made the mortise on the mortising machine. I cleaned out the mortise with a chisel until the handle tenon fit tightly into the mortise. Finally, I glued the two pieces together. And the project was done! I now have a sturdy and, I think, attractive mallet that should give me good service.

Could I have done anything differently? Definitely. My chisel was not sharp enough and I did a lot of unnecessary work paring out the mortise. I cut the thick stack of maple with a 3/8" band saw blade; a 1/2" blade made for resawing would have cut better, I think. And, I might have improved the looks by sandwiching some walnut in between the maple boards (or vise versa) to create a more patterned look. But, hey, it was all about getting practice with my machines and developing a sense of accomplishment. And that I got.