[Jewelry making - Article 00957] - [Orchid] Mallet making

[Dave]

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Hi, it's me again!  :)

    I've got another one of those "what am I missing here?" questions. 
    I recently bought a length of 2.5" diameter Delrin rod to make some
    forming mallets. I cut it into segments of the appropriate lengths,
    and bought some handles at a hardware store. I have read that
    handles with an oval cross section are better, so that's what I got.
    I've drilled two side-by-side holes as a start for the handle hole,
    but am having difficulty cleaning it out and removing the excess
    material. Any ideas/suggestions? Trying to use the drill bit to kind
    of grind it out isn't working very well. 

    I also understand that I'm going to have to wedge the handle into
    the mallet, since epoxy doesn't stick to Delrin. Any suggestions or
    tips here? 

Thanks, everyone, for all your help!
Dave

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