Unlike regular T-Joint, mallet has shruken cylindrical component forged with a big cylindrical component. Please guide correct mesh flow. https://i.stack.imgur.com/lobbx.jpg


At the beginning you could duplicate your cylinder and use the copy as the Target of a Shrinkwrap modifier so that you're sure that the circular hole you'll dig will stick to the cylinder profile. Then apply the Shrinkwrap and extrude to make the handle.

enter image description here

Also, you could use much less polygons:

  • Create a hole in the cylinder.
  • Extrude and make a circle with LoopTools > Circle.
  • In side view check that the circle's vertices are aligned with the cylinder profile (or use the shrinkwrap method if you think it's easier).
  • Extrude again to make the handle.

enter image description here

  • $\begingroup$ Awesome @moonboots ! shrinkwrap helped greatly esp. the 24+12 vertices setup. tried box modeling with subd but shrinkwrap gave what wanted. $\endgroup$
    – kumaran
    May 23 '20 at 11:32
  • $\begingroup$ Here's a great video tutorial that shows the Shrinkwrap process that @moonboots describes. youtube.com/watch?v=Ci1jBOm_5NY&t=1s $\endgroup$ May 25 '20 at 15:57

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