[Jewelry making - Article 01064] - Re: [Orchid] Mallet making

[marlin AT cohrs.org]

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    Delrin is a thermoplastic material, and as such it can be deformed
    or melted with heat. When I make my forming mallets from Delrin or
    nylon, I first drill a few undersized holes for the handle. I then
    take a torch and carefully direct the heat through the hole to
    soften the plastic in the hole. When it turns clear but not too
    liquid, I Force the warmed end of the handle into the mallet. The
    plastic then molds to the wood handle and acts like a glue  (kind of
    like a very hot melt glue) for a perfect snug fit. You must be
    careful, too much heat too fast and the plastic blackens and burns
    without softening enough of the material in the hole. or it can drip
    out and onto whatever is below, causing severe burns or a bit of a
    conflagration if it is burning. Too little heat and you will either
    not be able to get the handle seated or will get a cold joint where
    the plastic is not fluid enough to bond with the wood handle. 

Marlin in wet (we need the moisture) Denver.

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