Weighted Wooden Mallet

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Project by Homunculus posted 08-19-2014 12:51 AM 1253 views 0 times favorited 2 comments Add to Favorites Watch

This is a weighted wooden mallet I made out of scrap oak (the head) and the handle is a broken hickory maul handle. I shaved down the handle with a spokeshave, cut the top into a tenon and cut a slot for a wedge. Head is three pieces of oak with the long grain oriented lengthwise between the strike faces to resist compression during strikes. The head sides are solid but the center is bored out in several places and filled with metal fishing sinkers. Sorry I forgot to take a picture!. I ‘potted’ the sinkers with gorilla glue, so it expanded and filled the gaps between the sinkers and kept it from sounding like a baby rattle. After glue up I shaped it on my bench mounted belt sander then sanded to 220 by hand. Sealed it with boiled linseed oil, and glued leather scraps onto the strike faces with spray adhesive to keep from marring the struck surface. The color difference between the oak and hickory is really barely noticable in person, nothing like the two tone the pictures show.

2 comments so far

View NormG's profile


5424 posts in 2426 days

#1 posted 08-19-2014 04:19 AM

Great looking mallet

-- Norman

View Mean_Dean's profile


4943 posts in 2569 days

#2 posted 08-20-2014 12:05 AM

Good looking mallet! And interesting idea using the Gorilla glue to expand and keep the weights from rattling around. When I made my mallet, I didn’t do that, and you can hear them rattle a little bit.

-- Dean

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