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Big Darn Mallet

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Project by Kindlingmaker posted 1971 days ago 2578 views 3 times favorited 6 comments Add to Favorites Watch

I needed a wooden mallet for chiseling. Ok, I can make this. I had a 30 some year old sludge hammer handle in the outside wood pile ready to be cut for firewood, (It had been outside for plus 30 years. I procrastinate a lot.) Since it was hickory and was not split it would work so then what to use for the head? I had a piece of 5/4 red oak about 5” x 30” long so that would work. I cut the hickory to get the better part of the handle then used the band saw to make one end a rectangle shape about 1” x ¾” x 5” long. I then cut three pieces of the oak about 8” long then resawed one of them in half. The two full pieces of oak I dado cut in the center so they would fit the hickory handle. With TiteBond III glue I glued the two dado pieces of oak onto the hickory then glued each resawn half of the oak to each flat side of the dado pieces. After drying I used the table saw to square all the sides of the new hammer head then used the band saw to cut the approximate 12 degree face angles. The hammer head edges were then rounded using the belt sander and then touch up hand sanding. A heavy wipe on coat of varathane was applied. This hammer can now pack a good blow and at the same time be gentle. (I have no idea what this thing weighs but I will make a much smaller one the next time.)

-- Never board, always knotty, lots of growth rings





6 comments so far

View Alan's profile

Alan

443 posts in 1989 days


#1 posted 1971 days ago

Great looking Mallet. I’ve seen a few on this site and think I will try to make one soon. Thank you for sharing it.

-- Alan, Prince George

View Karson's profile

Karson

34845 posts in 2986 days


#2 posted 1971 days ago

Looks kind of how I made one about 2 weeks ago. I guess I’ll need to post it.

Looks great.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View WoodSpanker's profile

WoodSpanker

519 posts in 1977 days


#3 posted 1971 days ago

The Hammer of Thor, perhaps? :)

-- Adventure? Heh! Excitement? Heh! A Woodworker craves not these things!

View psquared's profile

psquared

46 posts in 2091 days


#4 posted 1971 days ago

If I had a hammer…there’d be no more folk singers.

-- When the tide goes out you see who's been skinny dipping.

View Kindlingmaker's profile

Kindlingmaker

2653 posts in 2112 days


#5 posted 1971 days ago

Karson I am looking forward to your hammer. When I went to make this one I found it difficult to find any information for making it. Sometimes it’s the most simplest of tasks that turn out to be the most ignored and the hardest to perform. Thank goodness LJ’s give freely their knowledge.
I will be singing “I got a hammer” all morning now!

-- Never board, always knotty, lots of growth rings

View Big_Bob's profile

Big_Bob

164 posts in 2294 days


#6 posted 1971 days ago

After reading your post I figured out that I too procrastinate! I think I will stop procrastinating tomorrow!
Anyway, keep working and remember the best projects sometimes do not cost much to make.

-- Bob Clark, Tool Collector and Sawdust Maker

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