Each cover is sewn carefully by hand with quality felts, chamois, synthetic leather, and inner coverings. The outer wraps are sewn to allow the player the freedom to voice the mallet according to their individual needs. I currently use three white timpani felts in the construction of the mallets (German, French, American). German felt is the softest, American felt is the hardest, and the French felt falls in the middle. The type of felt for each mallet is carefully chosen to match the desired character of each model.
Shafts
All of the mallets except for the #WC-7 are made with half inch by 15” long cherry wood shafts. Maple is also available (check with me for supply). Other lengths can be accommodated upon request, but I would recommend staying between 14.5” and 15.5”. They are sanded smooth and then given a Red Oak stain. Natural and Walnut finishes are also available at no extra charge. Several coats of high gloss polyurethane are used to protect the wood and leave a smooth, glossy finish. Satin finish is also available upon request. Other variations to the shafts can be discussed. Please specify on the order form and I will call or email to confirm.
Wood Cores
These cores are made of maple, a strong hardwood that will not break under pressure. Each disc and ball is matched up by weight and shape to ensure an even tone and then attached onto the handle with gap filling wood glue.
The cores are categorized by their shape. Ball cores have the largest surface area, producing the biggest, roundest sound of all the mallets in the series. All the other mallets come with a disc-shaped core. Discs are defined by the shape of the main playing area. Mallets listed with “convex” discs have a rounded playing surface that is uniformly rounded from top to bottom. Their articulation will be consistent no matter what angle they are played. Other mallets are made with “slab” cores. These mallets have a relatively flat playing surface for extra articulation and a rounded top edge for legato playing, giving them great versatility.
Specialty Cores
I am pleased to offer several mallets with alternative materials as their core. I am currently working with two materials: a red urethane compound, and UHMD (Ultra High Molecular Density) plastic. The red urethane core provides some cushioning for louder notes, giving a more even attack regardless of volume. The green UHMD is a bit heavier than maple. While still a hard material, it has a bit more “spring” to it. Both materials offer a consistent tone throughout the dynamic range, making them useful in virtually every situation. These mallets are categorized by core type.