Patchwork shop mallet, with attitude

  • Advertise with us
Project by JayT posted 169 days ago 937 views 0 times favorited 8 comments Add to Favorites Watch

Time for a new shop mallet, so went though the scraps and patched together this one using the two American hardwoods with the most contrary attitudes I have worked with—hickory and Osage orange (aka hedge, Bois d’arc or bodark).

Handle is actually part of a factory made hickory axe handle. The top was used to make a handle for a single bevel hewing hatchet, so the bottom was going to get tossed unless it found a use like this. Trimmed the top into a wedge shape, fit a couple larger blocks of Osage around it in opposite directions, then layered in the rest. After taking out of clamps, the head was squared and faces angled. I didn’t like the square look with the top being straight, so used a spokeshave to give it a slight curve.

Quick and easy project, but needed and useful. Heavier than my previous mallet and should be both more ergonomic and tougher.

Thanks for looking

-- "The American Republic will endure until the day Congress discovers that it can bribe the public with the public's money." Alexis de Tocqueville, 1835

8 comments so far

View woodcox's profile


575 posts in 645 days

#1 posted 169 days ago

Nice JayT. I’ve been thinking ordering some Osage to try out, I’ve never seen it locally. Seems a favorited dense hardwood for these types of projects.

-- "My god has more wood than your god" ... G. Carlin.

View Don Broussard's profile

Don Broussard

1950 posts in 885 days

#2 posted 168 days ago

@JayT—Looks like a nice banger there—good use of scraps. How much does it tip the scale at?

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

View Rick M.'s profile

Rick M.

3883 posts in 1014 days

#3 posted 168 days ago

Great combination for a mallet, nice springy hickory and hard as nails osage orange.

I have a couple hickory handles I’d like to use in mallets, any tips on cutting a square tenon on a roundish handle?

-- |Statistics show that 100% of people bitten by a snake were close to it.|

View JayT's profile


2187 posts in 845 days

#4 posted 168 days ago

Thanks guys

woodcox Osage is hard, tough and resilient, perfect for mallets. It is also a challenge to work with. If you can’t find Osage, black locust would be another good wood to use. The sawyer I got the Osage from says “black locust is Osage without the attitude”.

Don B I haven’t weighed it, yet. Have to do that one of these days

Rick M All I did was cut the top off pretty square and then marked off a rectangle on that surface. Just eyeballed the first line and squared off of it. Hand saws to start the cuts and finished with chisels. I did have to do a bit of trimming once the notches were cut in the Osage blanks, but not very much. I knew the notches/dadoes were square so that helped square up the handle.

-- "The American Republic will endure until the day Congress discovers that it can bribe the public with the public's money." Alexis de Tocqueville, 1835

View terryR's profile


3053 posts in 942 days

#5 posted 168 days ago

Nice mallet, JayT! Around here, Osage is used for fence poles by the unknowing. The saying is, “Place a stone on top of the osage pole, and when the stone rots, it’s time to replace the fence.”

‘Course I’m a wannabe bow maker, so Osage is sacred and highly sought after! :)

-- tr ...see one, do one, teach one...

View TerryDowning's profile


1004 posts in 751 days

#6 posted 168 days ago

Nice looking mallet Jay T!

I wish I had Osage/Hedge/Boi D’ Arc more readily available for projects like this.

-- - Terry

View Mauricio's profile


6809 posts in 1785 days

#7 posted 163 days ago

Sweet mallet man!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

View Fishinbo's profile


11217 posts in 809 days

#8 posted 162 days ago

Looks great, like the wood colors and grains. I’m sure it will be very handy around the shop. Great job!

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

Latest Projects | Latest Blog Entries | Latest Forum Topics :: gardening showcase