RV's Superior Quality Capped Mallet heads

Lots.
About 20mm either side of the pole, 4x round, pre drilled the pole hole for 4 rotations, and then some extra 10mm ish ones in the thickest parts. Not to mention a load in the head, but I am a weak wristed girl.

None

None, it's light enough already, and I'd worry it's so thin it may affect the strength.

25mm x 4 on the capped side and 25mm in the cap itself, the head's then pretty much balanced and is marginally lighter/easier to wield.

25mm x 2 on the top and bottom, either side of the shaft; so sides are untouched.

it was mostly the caps i was wondering about, is it better to do a pepper pot style or just one big hole like jono said

I don't think it makes a lot of difference, Woody... I've pepper-potted, big-holed and kept it honeymoon fresh... You'll lose more weight with a big hole...

Yeah Woody, get back to Candia.

You also save a lot of weight if you rotate your head when it starts to wear... I drill six holes, alternating between 14mm for pole and 6mm for M6 bolt, along the centre line of the head... The head I'm playing on now is on it's last rotation, it's mega-light...

Think I'll make a big hole in cap, four x speed hole version like Jono's next time up...

Yeah, I was doing smaller crosshairs (peow, peow) before, but now have one big hole (less faff).

If you are going to drill the cap, why not do it from behind and try leaving a thin layer on the cap?

That sounds faff-tastic Louis...

how would you extract the bit removed from the inside?

i get what he is saying, slowly and carefully drill form the back with one of these. then you get nice shaving in a wide circle from inside and a small hole on the outside.

got it, in my head i was thinking about one of thse

CSB

^^^^
I don't bother drilling heads at all, so didn't think it would be much worse... But I'll take your word for it.

Strong wrists for the win

#wanker

^^ yep that's what I was thinking, as I have one in exactly that size

If you are going to drill the cap, why not do it from behind and try leaving a thin layer on the cap?

that definitely wouldn't work with a holesaw, the holesaw can only make a big hole, you cant just remove some material.

When i make caps, i use a forstner bit to remove the material inside the lip.

[

](http://upload.wikimedia.org/wikipedia/commons/thumb/5/57/Forstner_Bohrer_01.jpg/220px-Forstner_Bohrer_01.jpg)
but using that after the cap has been bonded isnt going to be fun.

thats lathe porn right there!

I concur with Pique, TS, and John H. No drilling necessary.

it was mostly the caps i was wondering about, is it better to do a pepper pot style or just one big hole like jono said

I don't think it makes a lot of difference, Woody... I've pepper-potted, big-holed and kept it honeymoon fresh... You'll lose more weight with a big hole...

Yeah Woody, get back to Candia.
That's not Woody, I thought it was Wayne?

fucken Wayne

So I've had 2 heads break with the cap coming off after very little use. Am I doing it wrong?
#sadface

Too strong for your own good

I'll send you some replacements for free , those ones were probably possessed by evil spirits.

Trust me to get the Voodoo heads.
That's really kind RV, much appreciated.