How should I join Delrin to wood?

[Mark Stewart]

Why not do the mortise with a recess grove inside with the plastic stuff cut a bit oversized for press fit kind of thing?

 

[Alan in Little Washington]

Hangar bolt or turn and thread a tenon on the back of the Delrin face and drill and tap a hole in the mallet body. It would only take 5 seconds to remove the old and thread on a new Delrin face.

 

[Rick M]

Both good suggestions. I considered the snap fit but am concerned it may become loose with wood expansion/contraction. Threading is a great idea but that ipe is so hard it will probably ruin my carbon steel taps/dies. If I had HSS taps I might have tried it. In any case I have the steel dowels now and will use those.

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