Damascus Mallet from plastic bottles
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- Опубликовано: 10 июл 2018
- In this video I'll show how I turn a bunch of plastic bottles into a Damascus pattern head HDPE carver's mallet to be used with my hand tools. It's a great opportunity for upcycling this type of plastic that we all have around. Processing HDPE is really tedious but the result deserves it. Besides, this material will last you more than any other wooden mallet head. In all previous videos about melting HDPE only show one way, using a kitchen or portable furnace. At this time I was likely to experiment using a tool that is present in most of the workshops: a heat gun. I may take a little longer, but It's easier to prevent damage to the plastic. During this video I also show how to repair small voids or defects. Also, I hope you enjoy this project. Leave your comments and questions. I’ll be pleased to answer all of them.
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This video is inspired by: • DIY HDPE Damascus Mallet 
Развлечения
That looks awesome! =) Few tips for you though, based on my experience working with HDPE. (I made a roller trailer for my boat with 28 rollers all made out of recycled milk jugs.)
1. A toaster oven set at 340 degrees F will be a lot less work than layering & waiting for the heat gun to melt the plastic together. Using the heat gun, make sure you don't overheat the plastic or are outside - HDPE starts off-gassing toxic fumes at about 400 degrees F.
2. If you apply epoxy inside the female end of a mortise/tenon joint, more adhesive will stay in the joint. Applying it to the male end and then shoving it in has the effect of the edges of the female side scraping off epoxy which might be useful down inside.
3. When turning something that's heavier on one end than the other on your lathe, you'll get less vibration if you put the heavy end nearest the headstock.
You certainly have more guts than I do! I tried cutting round stock how you did on my bandsaw one time - saw grabbed the log, spun it around about 729,000 rpm, threw it across the shop, and the saw almost bit me. I'm certainly not one to try telling anyone how to work in their own shop, but please be careful - I like your videos too much for you to get hurt & not be able to put out more. ;-) =)
I truly thank all the time you inverted in share all that useful information. I'll keep it for the next time working on HDPE, which is going to be really soon. About your concerns ofsafety, my workshop has a really big door (like 4m tall barn door) always open while I'm on it, also with a window open to produce air flow. I'm also wear almost all the time 3M FPP3 dust mask. Best regards!
This is such a cool and educational comment
finally found the good side of RUclips : real people sharing useful info and being respectful. thanx both for the tips
Otto Didakt amen
729,000 rpm? That is around the frequency of AM radios (535-1605 kHz)
Or did you intend this as humor?
The only time I saw anything move that fast in my shop was when the wife called me for dinner.
(insert laugh track...)
That last shot with the mallet and the knife was absolutely perfect.... The angle, the lighting, the use of the tools.
Thank you Arturo. That was also my favorite shot of the whole video. Regards!
Agreed
I've seen a lot of plastic mallet videos, but this transcends the lot. This is straight-up high craftsmanship, equal to anything worked in hardwood. Thanks for the beautiful video.
I trully thank you Rob. Regards.
I'm a professional woodworker (like I am sure all the commentors are) and I think this is absolutely AWESOME! I have wanted to melt some plastic into a usable object, but there is not a lot of down time in our shop. I am walking in after the holiday break and setting up a small run of these. I'll give you and this video credit for the inspiration. Best regards from Texas.
Thank you man! I'll hope to see your mallets some day. Please let me know when you have done. Best regards!
Finally I've found someone in Catalunya that does woodworking for a hobby...
Haha, I'm sure I'm not the only one ;D
This kind of out-of-the-box thinking always impresses me, not to mention the craftsmanship. I won’t ever likely have access to these wonderful tools - but I would surely support a Kickstarter campaign to see someone build a business around tools like this! (Extra kudos for the artistic shot at the end of using the mallet to drive a chisel carving that perfect curl of wood!)
I feel rewarded with this kind of comments. You keep me doing this. Best regards!
Extra kudos guy is the same guy lol
Marc McKenzie ...isn‘t it just advertising for wonderful tools?
I don’t understand why people thumbs down these videos, but leave no comment to justify it....to think out of the box and create something by hand over time deserves a respectful pat on the back.....well done chap, good effort 😉👍
Neither do I. Anyway the comments like yours compensate for those thumbs down. Regards and thanks for your support!
Man, this turned out so freaking cool! I really want to try this now, I absolutely love the look.
Thanks Johnny, it's good to see you again. Thanks for come and comment. I'll be glad to see your HDPE mallet when is done ;D. Regards!
That's so mesmerizing to watch you squeeze the metal into that can, turned out really nice!
Thanks man! It's no metal at all, its called HDPE (High-density polyethylene). Regards!
Sanding and polishing on a lathe is a form of happiness!
Fully agree 😁
Fantástica idea compañero, muy ingenioso 😳!!. Y la mesita de noche....Wow a mi pareja le ha encantado, una maravilla y un trabajo finisimo. Saludos Crack
Muchas gracias compañero! Esas mesitas de noche me dieron mucho curro, sobretodo porque cada una tiene sus detalles particulares. Un abrazo y gracias por comentar!
This is a super interesting project! I loved the video and the recycling of the plastic. Also, the Damascus effect is top notch!
Thank you Chris! I've made two other HDPE mallets a year or two ago, but they were monochrome (no visual interest at all). When I realised that the milk bottles that we consume had 2 colors (white/gray) it definitely moved me to try again and I fell in love with this beautiful Damascus pattern. Regards!
kinda looks like stone
Get Hands Dirty h
Recycling is a big word considering all the electric energy used to melt it..
Nico....shut up
Impresionante esté damascus y lo bueno que tiene que lo puedes reparar en cualquier momento. Buena manera de reciclar. Un saludo
Gracias tío! Ya ves que los que no sabemos de metal nos apañamos con el plástico jeje. Ahora en serio merece la pena tener un martillo de cabeza de HDPE o Nylon. Se trabaja mucho mejor golpeando formones. No dañas los mangos de madera y responde casi casi como un dead blow mallet. Un abrazo!
@Woodworking Barcelona HOLI ME GUSTO 3L V1D30
Always amazed at what you can create with your own hands, the right tools & a little imagination...
Looks great..
As someone else said..love to see that with coloured plastic in it..
More please...
Thank you Alan for your words.
I have no idea why I watched all 12 mins, 11 seconds of this video, I only know I couldn't stop.
Nice! Check out my recent videos. Hope you enjoy them as well.
Saving the planet in a beautiful and practical way. Thank you for posting 🙏🏻
Thank you!
Awesome video and awesome details. Beautiful mallet Lluís!!
Thanks for come and comment my friend. I kind like to show with more detail all the steps of the process. Regards!
Love the use of the mallet to build the mallet
Mallet life cycle.
Gotta admit, I didn't think I'd like your style of video production at first, but you won me over. Very well done.
I'm glad you finally liked it 😉
Very cool mallet. Now I can cut all of those plastic jugs into strip an fire up my heat gun. It's much better than burning them in the trash pit. I can already visualize mallets with swirling colors. I have about 50 empty jugs in blue, yellow, white, clear, and red too. A marbled effect would look really cool. Thanks for the incite.
That would be interesting to see. Regards David.
Wow, I liked the way it was filmed and presented without music just the sounds of working. The effect that comes by trading the handle with wax (I guess) is so satisfying :) great work, thanks for the upload!
Thank you for your positive feedback mate.
Very cool!
I truly thank your visit and comment John! Regards!
I must admit that this idea would never have occurred to me. Kudos.
It's always nice to see people sharing their new techniques for working with plastic. I wouldn't have thought of layering it together with the heatgun!
I'm currently trying to figure out what materials are strong enough to be used as a hammer, anvil, tongs, etc. on hot HDPE without it sticking, to "forge" it, similar to blacksmithing. Reason being that HDPE "ingots" or "bar/round stock" take up far less space than shredded bits. As well, "forging" hot HDPE is simply an unexplored territory with regards to what is possible vs machining and "plasticworking" it.
Plastic is such an interesting material and I think it will only get more interesting as people outside of an industrial environment experiment with it.
Hi! Very interesting. Thanks for share your thoughts. I'm sure this Mallet won't be the last project using HDPE. Best regards!
Aubreykun PET might be good as it is less rigid than some other plastics and as such might be a bit tougher. It's the clear bottles.
+Anonymouspock
Hmm... I may have to try touching some PET to molten HDPE and seeing if it will stick to it. If it works I'll figure a way to fasten it to a hammer. Thank you.
If you think you are so awesome because you can make stuff like that, well... You are. Great stuff. Love your work.
Thanks!
Looks like a WWII German Stick Grenade.
"Fire in ze hole."
We didn't call it a potato masher for nothing!
stielhandgranate
Achtung!!
I was just about to make the same comment.
That what all the guys said about my whore of an ex wife after she shared her clap with hundreds
You are a very talented young man . My goodness I’m impressed at how you used the tools you have on hand . Heat gun was brilliant as was the way you used all your tools. 👏👏👏👏👏👏👏👏👏👏
Thank you Cathy! It's very rewarding to hear that. Thanks for support my work. Best regards!
Thank you for this! This is such a great idea. I have wanted to work with plastic but didn't feel like I had the right set up for it, but this is awesome
Amazing job!!!! I love the look👌👌
Thanks man! ;)
That golden ratio carve shot at the end though... Golden!!
Thanks mate! IMHO this is the best shot of the whole video. Regards!
My english sucks and I have no idea what mallet is, but I'm a huge fan of the way melted plasic bottle looks like. It's beautifull.
And it's few less botttles in the ocean.
P.S. -Finally i've found ASMR which don't annoy me. I'm staying here.
Thank you for your words Angelika!
PARABÉNS...., meu Amigo, ficou maravilhoso o malho, quanta habilidade e carinho!!!
Obrigado por compartilhar comigo seus conhecimentos.
Abraço aqui do Brasil 🇧🇷
Obrigado!
Great job on the mallet friend! Thanks for sharing the video.😎👍JP
Thank you JP!
You're very welcome Friend! 😎
Where in the hell do you get a badass clamps like the ones you're using those are the most impressive clamps I've ever seen. I've been doing this for 40 years too.
Those are the most badass clamps I've ever used, the Maxipress from Piher company.
MAN this has to be the coolest thing I've seen in a while, my upcylcing senses are tingling. Heading to the workshop right now :D
I'm glad it inspired you. Regards!
What a great project! I am definitely going to give it a go, but I cannot fathom the 436 hopelessly negative people who gave the video a 'thumbs down'. Probably Pfeil and Narex employees who see a potential drop in mallet sales.
Thanks Tony. I guess many of those thumbs down are from people who are not agree with my use of the word "Damascus"... I don't care about that. The purpose of my videos is far away from that kind of discussions. Regards!
Those are some nice clamps! (Like the mallet too, and love the plastic melting/forming process. You've inspired me. Thanks!)
Thanks, that's my goal. I'm glad it inspired you.
Awesome work man! Really cool idea to use the heatgun that way!
Thanks mate! It's not the best tool to do so but I have no oven on my workshop so I had to improvise. Regards!
Will that only work with certain types of plastic? And would mixing in a 3 part epoxy as a binding agent increase strength or hardness?
I've no experience in other plastics. No need to use other than 2 part epoxy. The bond between wood and HDPE is pretty strong. This mallet has been abused and it holds fine.
HDPE melts at a lower temperature than other plastics... so easier to melt/mold, and dunno, but guessing lower temp = less risk of toxic fumes.
Thank you for sharing !!! Really nice idea for a Mallet!
Thanks, I'm glad you like this idea.
Loved you video, the way you do things, with such a calming effect...keep it up!
Thank you very much!
This is soo cool!! What a great use of plastic 😀Turned out awesome! We love the patterns it created!
Thank you, I love to use it.
Wow. Just wow. May be one of my favorite projects of yours. Can't wait to try this! (Yes, I shamelessly attempt to copy your projects.) Thanks for the inspiration and thanks for sharing.
That's awesome! I feel very rewarded to be able to inspire other people. Please feel free to share your experiences and projects with me via Facebook or Instagram. Best regards!
Wow man very impressive. Love seeing people use recycled material and make it look like it wasn't. I'm gonna borrow this idea I just got a bunch of new gouges and you can never have to many tools to bang them with.
I'm glad this project encouraged you to make one by yourself. Good luck!
Beautiful design & fabrication. Lathe turning was a very revealing experience. For your information 130° C or 266°F is the recommended temp to mold & shape HDPE without releasing harmful vapors due to off gassing.
Thanks for your thoughts and recommendations Sean.
Really interesting project - I definately think this material has a lot of potential!
Thanks. I bet this is not my last project with HDPE.
Love it!!
Thank you Matt!!
Quin nivell d'espectadors que tens :O
Dani Doncs sí!
Yes ME TOO
You had me worried there for a minute with the heat gun and screw driver! Came out looking awesome !
Haha 😬 I did not fail. It's really easy to patch those bubble air holes with more HDPE. Regards!
And with the patience of Moses you have a beautiful mallet.
Thanks Leon! Real patience is for filming and editing the video
Dude I was so into this video I didn't realize how close I was to my screen lmao
lol, that's great!
Qué trabajo más exquisito, en todos los aspectos del vídeo. Impresionante!
Muchísimas gracias Miguel! Me alegro que te haya gustado tanto.
@@WoodworkingBarcelona Estuvo Genialisimo!
Excellent job sir.
I particularly liked the clamp for the heat gun.
I shall be using that too.
Thank you.
Thanks you!
Never thought to use a heat gun! Looks like a lot of time and effort went into this - well done man!
It looks like and I really was but I have not an oven on my workshop so I had to become "imaginative". I'm glad you like it. Regards!
Nicely done!!! Thinking in terms of color varieties of the plastic. And PLEASE wear eye protection, I want to see you do more videos.
I do, thanks for your concerns! Best regards Jay.
Stielhandgranate with custom skin...
Lol
abhishek gourav lmao what
@@swsdnnogdner4726 Stielhandgranate is the german ww2 stick hand grenade.
Roblox oh
awww you beat me to it
Great camera angles. You are a talented videographer and woodsmith. Thanks.
Thank you for your kind words Bakersman!
Very cool!! I love the random patterns of the plastic 👌🏼
Thanks! I found those really beauty.
Cool project.
I'm gonna be the boring teacher guy though, and point out that it's cuite dangerous to cut cylindrical objects om the band saw. It's not obvious why, but whe have had several accidents in my shop, when the band catches and the cylinder starts to roll.
If you want a safe setup: support the cylinder in a block of wood vith a V- shaped slot, or a bord screwed on a piece of plywood, making an upside down T-profile. The point is to support the cylinder or pipe at two points of it's circumference. This prevents rolling. Btw, splitting a cylinder is even more dangerous.
Thanks for your thoughts!
It's Daplasticus 🤓
Turned out great!
Lol thanks!
Beautiful mallet. The concave end was cool.
Thanks man! I think it's a must to make the end of the head concave. If not, you're not able to keep it from falling from your workbench every time.
One of the best mallets of seen yet
Thank you!
Off-screen when cutting plastic Darth Vader breathes. 1:10 :-))
I can be exhausting to cut by hand all those plastic bottles, you know.
Woodworking Barcelona I've seen many office shredders that say they can handle CDs & credit cards... Wonder if you could find one used? Or even inoperable, sold as salvage. I've brought many a curb-find back to life. 😎
Que pasada!
Gracias Juanki. Me alegro que te haya gustado.
Nice work and thank you for the inspiration to make one for my wood chisel tools. Current hammer is a double sided rubber mallet. Soon to be replaced by your great idea.
Thanks for your comment!
Cool look and an awesome use for the old bottles
Yes indeed. Thanks for comment!
You were supposed to fix the chip with ramen lmao smh
I don’t get this dumb trend … this doesn’t even work let alone being durable.
I'm kind bored about that... I prefere to eat ramen.
Totally agree
Hello from 2019 and that looks like a german stick granade
Yes but was totally unintended.
This is great looking into plant based glues and organic varnishing oils is a great way to make woodworking more sustainable
R R Thank you for sharing your creativity, I've always been one to never work from plans, I have simply thought of what I wanted to build, I could see the end result and went to building it, from you I have gained an even greater appreciation for working "off the cuff," I would like to see more of these things you create. Best wishes in your future endeavors.
Thanks for your words Raymond.
@@WoodworkingBarcelona your very welcome.
Amazing! I'm going to have to try this rather than buying a new woodcarving mallet!
Sure! I recommend you.
Really nice :) But safety glasses ;)
Thanks for this vid !
Thanks for the advice 😎
Here you are ;-)
What do you use to remove grease matter from HDPE Bottles? Is water and soap strong enought?
Gran trabajo!!!!!, me alegra mucho de que hayas utilizado madera de encina muy dura por cierto,sigue asi te has ganado un like y un suscriptor, un saludo
Sin duda! Es de las maderas más típicas de la zona así que no hay motivo para no usarla. Un saludo!
This is so cool! It's a great upcycle too! ❤
Thank you David.
Unsure if anyone has mentioned this, but you could probable run those wide plastic bottle strips through a paper shredder machine. Might save some time. Great video, Nice talent.
Hi thanks! Yes indeed, many people has given me the same advice. I appreciate that. Regards!
while the plastic was liquid, you could immediately insert the handle
Yes I could do so but I do trust better the way it hold with epoxy.
Actually turning the shank (with protrusions to grip the plastic) along with a handle and a disk to compress the plastic as one unit and then refining the whole thing after the plastic hardens on the lathe would save a lot of materiel and steps. I'm not sure epoxy does well with hdpe as it's kind of notorious for being incompatible with most other plastics.
@@phookadude Maybe this is a project meant for fun and not mass production so he does it the way he likes to? lol
@@WoodworkingBarcelona your trust is misplaced almost all epoxies wont bond to HDPE, HDPE is what i use with epoxy to protect thigns from it sticking..
Have you used the mallet a lot? If you have, has the plastic held up to use well? Nice project.
Increíble! Menudo proyecto tan trabajado y vaya talento el tuyo!
Muchas gracias Miguel Angel.
Excellent workmanship and beautiful mallet.
Thank you!!
I think you should have feed the sheets through a high quality cross cut shredder.
My thoughts as well.
Oh please, send me some of yours. It would be great because I dont have one.
I just have the one. I send paper to the compost bin and then the garden. Now a new idea.
Sure do love microplastics.
👍
BRAVO!! Muy bien todo el proceso, y la solución al accidentillo. Muy creativo. 👏👏👏👏👏
Gracias Jordi! La verdad es que el HDPE es bien facil de reparar. Gracias por pasarte a comentar!
Amazing! So practical! And beautiful!
Thanks for your comment!
It's a Zaku 2 (Stielhandgranate) stick granade
It looks pretty similar but I has a better use I think.
I'm surprised the epoxy and hot glue adhered to the HDPE. I've made mallets and forced the wood handle into the liquid HDPE in order to get a solid bond.
As far as I've been working with it, the bond stills secure. The approach you use it is also great.
Absolutely beautiful! Nicely done...
Thanks Kat!
Very simple and very effective, and very enjoyable to watch 👍
I glad to read that. Thanks
Me: Why do you talk so slowly?
Him: It's because
of the
plastic fumes.
😁
FPP3 and well ventilated room here, thanks.
@@WoodworkingBarcelona I was just kidding. 😁
The end result is great!
However, I don't understand where the black color comes from.
The bottle was white, was there a second black bottle we didn't see or does it simply gets that way when you cut it into chunks?
The bottles I use have two layers of HDPE, each one with a different color (white/Grey). When the gray is affected by heat it increases the color to dark Grey. That's all.
The internal layer is a different color
tons of patience, questionable workflows, cool square lathe tool, satisfying procedure, *excellent outcome.*
Thanks!
Thank you a lovely mallet and good technique 😄👍
Thanks you Ray!
From Ingot to Mallet with only a wood lathe and a heat gun. Eat that Alec Steele.
Haha
Leave Man-Puppy Alec alone! 😂
That's it I'm getting me mallet.
👍
Hermoso trabajo,debes sentir un enorme placer al utilizarlo con tus herramientas manuales,felicitaciones
Mucho! Gracias por tu comentario Álvaro.
the best part of watching latheing videos is the varnishing on the lathe
I totally agree!
So, how many bottles did you use for this project?
About 15
Wow... that is a bit higher than i expected!
Would a crosscut paper shredder work to cut the plastic bottles into pieces? Mine can cut credit cards, so it should work once you have some wide flattish strips. Great mallet and use for upcycling!
I think that will do the thing. Unfortunately I don't have any paper shredder which don't justify the cost for making only one of these mallets. Thanks for your comment!
Your paper shredder may work if it's that powerful but it could be hard on the machine and shorten the working life of it. Precious Plastic has made a (free) design for a shredder which can pulverize entire bottles if you wish to spend the time and money and effort to build one
In my particular case is not worth all that effort for making only one mallet. Thanks for your thoughts.
Very cool machinery, Aubreykun, never knew how many people were upcycling this way. My paper shredder is relatively inexpensive ($50 US) compared to that machinery, and the metalwork machines. But for large production that would be different. I could probably use the shredder to make a single mallet without harm since it's designed for cutting credit cards which are thicker and harder plastic than the bottles. You'd have to rest it after about 5 or 10 minutes of use, but that's true for paper shredding, too.
I was just typing out this same thought on the crosscut shredder idea =) glad I checked the rest of the comments first...
Absolutely incredible!
Thanks Charlie!
CRAZY cool project, love it...
Thanks!
A paper shredder might take some of the tedium out of
cutting up the bottles into small pieces.
Sure but I've don't have one.
Hey, bro! Use the goggles, please! Great work)
I usually wear them.
I don't have any tools or do any carving, but these are amazing to watch! THANKS!
I'm glad you enjoyed it Lou!
Great idea! One could also use spent gift cards or any preferred plastic.👍🏽👍🏽
Indeed but you always have to make sure it's HDPE.