Visit to Trusty-Cook

I thought it would be interesting to visit the factory where our steel shot, dead blow hammers were fabricated. And since they’re conveniently located here in Indianapolis, I reached out to Joel Trusty for a visit to his plant. The photos below provide you with a perspective on the process.

The “Skeleton” of the hammer consists of the handle and the head; the handle is welded to the head. Note the steel shot in the bin. This is what makes the dead blow hammer so effect- much more so than your typical hammer.

After a freeze plug is affixed on one end of the container, the steel is added. The steel material is recovered from blasting, such as in nautical applications. Then, the other freeze plug is added and the contents are “capped.”

Joel Trusty is holding the framework for the hammer model that we use for the Firefighter Combat Challenge before it’s put into the injection mould. The hammer works best at room temperature- not in freezing conditions. Also, as in our setting, rotating the hammers adds a lot of life, because heat causes the hammers to change shape. 

This is one of the moulds for the short hammer, a perfect solution for stubborn gate valves or steamer connections on an engine. A much better solution than a bowling pin- if you can believe that. 

Now, the skeleton, first seen above is placed in the mould. The pins hold the frame in perfect alignment.

The frame of the hammer is held precisely in place with the positioning pins before the lid is affixed.

The mould is now ready for injection of urethane. The hammers can be made in a variety of colors. 

This is the vat of liquid red urethane. The injection process can produce bubbles. These simply cosmetic and have nothing to do with function. 

The pump injects the plastic into the mould, hence the term ”injection moulding.”

After curing with infra-red light, the hammers are ready to be trimmed and labeled. 

Hammers of all sizes and weights are fabricated daily and shipped to dealers and distributors around the world. One overlooked application is the 14 pound sledge, the perfect tool for forcible entry. One sack and you’re in! We’re picking up the line for use on engine and truck companies. The hammer will be on display at our store and on our website.