HDPE Mallet - AKA Milk Jug Hammer

[mr95gst]

I have been wanting to try this for a while. I started saving milk jugs several months back along with some other random HDPE containers I found. It is surprising how many containers it takes to have a have enough HDPE to make a block like I did. I would estimate this hammer took between 20 to 25 jugs. The initial block turned out very well. It more heavier than I expected and had no void. While the chips were still hot I folded them together several times and I think that worked out any air pockets. I started melting at 275 F but ended up around 330 F. Most of jugs were either white or clear/opaque. The color came different lids. I squared up the block on the table saw and then smoothed it out with the belt sander. The surface finish is smooth and feels like a bar of soap but it much harder. I guess it looks like a giant piece of candy because when I handed it to my 3 year old she immediately tried to taste it.


*****PHOTOBUCKET HIJACKED MY PICTURES SO I HAVE EDITED THE POST TO ADD THE PICTURES BACK. THEY ARE NO LONGER IN ORDER TO MATCH COMMENTARY MADE WHEN THE THREAD WAS STARTED. MORE PICTURE AT THE END OF THE THREAD

Processing the jugs:
Melting the chips:
Melted HDPE in mold:
Side 1:
Side 2:
Sanded:
Hold for handle:
Handle from shipping pallet:
Finished: