How to melt PET bottle caps into a useful tool

An ordinary round wooden mallet is prone to cracking along the grain if it is not used exactly as intended. Using plastic waste, you can make a very beautiful, more durable tool.

What you will need:

• pipe;
  
• Sheet steel;
  
• corner;
  
• bolts M8-M10 – 4 pcs.;
  
• HDPE waste;
  
• wooden blank for the handle.

The process of making a round mallet

It is necessary to select a pipe whose internal diameter will correspond to the circumference of the mallet. A piece is cut from it to make a mold for casting plastic. A base for mounting the mold is cut from sheet steel.


4 blanks are cut from the corner to attach the mold. On one side, a hole is made in them, and a thread is cut into it. A pipe circumference is drawn on the base. Fasteners are welded to it at the corners.



4 plates are welded to the pipe so that when it is placed on the base, they can be tightened with bolts screwed into the corners.


Waste HDPE plastic is placed into the mold. These are products that are marked with the number “2” in a triangle.Plastic canisters, bottles for yogurt, shampoo, household chemicals, and caps for PET bottles are suitable.



The mold is placed in an oven heated to +200°C. In about half an hour the plastic will soften. You will need to compact it with a stick and add more waste. This is done several times. By alternating HDPE of different colors, the mallet head will get beautiful stains.


Plastic takes a long time to melt and compact. This time should be used to sharpen the handle for the mallet. Also, a plug is made into the mold from plywood using a core drill. A hole for the handle is drilled in its center.


When the mold is completely filled with plastic, a plug is placed in it, and a handle is driven through the hole in it. A long tube is placed on top of the handle and rests against the plug. By hitting its end it is necessary to compact the plastic.



After cooling, the plastic is knocked out of the mold and turned on a lathe. The open part of the handle is soaked in oil.

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