Wooden Jarrah Sledge hammer

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Project by robscastle posted 08-30-2014 07:11 AM 2153 views 1 time favorited 7 comments Add to Favorites Watch

I was working at Smiths Crisps repairing their potato crates and in the process managed to recover some deckboards and bearers.

It was my intention to make a piece of furniture with them, and started a project.

I had a good look at them for Foreign Objects and the bearers in particular were riddled with nails and the occasional screw and some bolts.

There was enough safe areas to Joint then but that was about all.

All the nails I though I could pull out and leave a few of the bolts as a feature.

But that was not to be and I was not prepared to hit a nail whilst working.
The other factor was I was not sure if my bandsaw could cut them and not ruin the blade in the process,

I found some suitable pieces in the deckboards to make the base of a seat, so I set to work on them leaving the bearers.

Whilst I was waiting for the glue to dry on the pieces I selected for the seat I turned my attention to the bearers to see just what I could use them for.

Not a lot but I had a idea that I could use some small pieces, so I decided to make the Sledge Hammer


The Head:
The head was cut from a section cut between the nails, I then sanded the 45 deg edges on it and used a 22mm forstner bit to drill out the handle hole.
After some sanding it was completed.

The handle:

I ripped a piece off the wider boards for the handle, then cut a radius on to the edges and then sanded it to fit the hammer head hole, for this I just used my disk sander.

To make it look reasonably realistic I then cut a wedge section in the handle assembled everything using Titebond III to ensure everything should stay together.

To add some more authenticity I then sanded some nicks and dings in the handle to give it “that used look”


I sanded it all to 800G and applied a coat of Howards Products Citrus Shield Paste wax.

This brought it up a treat.

I will keep working on the Seat and post it upon completion however working with recycled timber to produce furniture is testing me.


-- Regards Rob

7 comments so far

View BobWemm's profile


2553 posts in 2123 days

#1 posted 08-30-2014 07:27 AM

Looks just like a real one, but I’ll bet it is not as heavy as mine.
Great job.


-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View stefang's profile


16123 posts in 3531 days

#2 posted 08-30-2014 08:01 AM

Looks great for driving wooden dowels Robert. Very good replica.

-- Mike, an American living in Norway.

View robscastle's profile


5435 posts in 2401 days

#3 posted 08-30-2014 08:07 AM

Thanks Bob and Mike,

I was thinking of using some silver Rub and Buff on the head to make it look even more realistic.

Yes its fully functionable and you could use it as a mallet!

-- Regards Rob

View David Dean's profile

David Dean

608 posts in 3096 days

#4 posted 08-30-2014 08:25 AM

nice job and it looks real.

View Boxguy's profile


2756 posts in 2464 days

#5 posted 08-30-2014 06:21 PM

Robert, what nice work. It looks realistic and would be a great tool for setting the burr on a lathe. Jarrah is pretty dense, but a lovely wood. A smaller project like boxes might be better than furniture. Such rough stuff is hard to get any lengths out of. This is a fun project, thanks for sharing it with us.

-- Big Al in IN

View Joe Lyddon's profile

Joe Lyddon

10320 posts in 4249 days

#6 posted 08-30-2014 08:57 PM

That is one BRUTAL Mallet…. Hammer!!



-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View MakingCurls's profile


43 posts in 1776 days

#7 posted 08-31-2014 02:24 AM

looks formidable. very nice work mate. i’ve done a fair bit of training at sandvik around the corner from smiths

-- Out in the shed making curls

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