The head I made the other day seems to be working realy good.
The extra weight realy makes it easier on my wrist... not having to hit so hard. Thats probably what killed the other heads was that they were too light. My mallet handle is different such that it is rectangular and tapered fit. It's a bit harder to make the heads but it has a good stable feel when using it.
Anyways thanks for the help and the conversation guys.

Thane