Osage orange mallet

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Project by Pezking7p posted 07-01-2014 11:09 PM 3667 views 4 times favorited 12 comments Add to Favorites Watch

This is my submital for the 2014 mallet swap. The internet told me that osage orange is good for mallets so of course I had to use it. The handle is made from figured maple. The mallet is very heavy and best used for heavy chopping or “persuasion.”

Other than the initial milling and sizing, this mallet was made entirely with hand tools. The head was shaped with hand planes, including the chamfers. The handle was shaped with a spoke shave and attached to the head with a simple mortise and tenon.

The head was not completely dry when I started working and it split pretty badly in some areas. I smashed a chisel for a while to make sure the cracks wouldn’t tear the mallet apart, then began filling the cracks with epoxy. I used a shop vac to suck epoxy deep into the cracks and ensure they are completely filled.

The handle is stained with trans tint dark brown or something like that, then sanded back to expose the figure. The chamfers on the handle were left stained for visual contrast. A few coats of clear shellac finished the handle off. The head was finished simply with BLO and wax.

Thank you for looking!

-- -Dan

12 comments so far

View 489tad's profile


3857 posts in 3811 days

#1 posted 07-01-2014 11:28 PM

A little blood, a little epoxy, what more does a mallet need? That Osage looks nice and you picked a nice piece for the handle. Well done.

-- Dan, Naperville IL, I.G.N.

View 7Footer's profile


2575 posts in 2748 days

#2 posted 07-01-2014 11:52 PM

Very nice job Dan, that osage is fuggin awesome, how is it to work with? Great shape on the handle too.


View ShaneA's profile


7085 posts in 3398 days

#3 posted 07-02-2014 12:01 AM

Well done.

View Mean_Dean's profile


7047 posts in 3947 days

#4 posted 07-02-2014 12:11 AM

Very nice!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View Pezking7p's profile


3358 posts in 2451 days

#5 posted 07-02-2014 12:56 AM

Thanks for the kind words guys.

7’er, the osage was pretty easy to work, it made beautiful thin shavings. It was a little hard on the tools, though.

-- -Dan

View Hammerthumb's profile (online now)


3055 posts in 2775 days

#6 posted 07-02-2014 01:50 AM

Used it for a few minutes tonight. Sure packs a wallop! It will be great for mortises. Just what I needed. Thanks again Dan.

-- Paul, Duvall, WA

View Mr. E's profile

Mr. E

108 posts in 2467 days

#7 posted 07-02-2014 02:44 AM

I’ve used an air hose to blow epoxy around. Quite messy at times. This shop vac idea sounds brilliant. Great execution!

View Slyy's profile


2840 posts in 2455 days

#8 posted 07-02-2014 04:25 AM

Any idea where this fella clocks in for weight? I added bird shot to my submission hoping to pump it up some.
I remember ruining 2 chainsaw blades cutting some hedge apple down for my dad back in high school! It some tough shite fo sho!!

-- Jake -- "Not only do we live among the stars, the stars live within us." - Neil Degrasse Tyson

View Sanding2day's profile


1015 posts in 2646 days

#9 posted 07-02-2014 04:42 AM

Nice work! Thanks for sharing…

-- Dan

View Pezking7p's profile


3358 posts in 2451 days

#10 posted 07-02-2014 12:43 PM

Jake, it’s heavy. I didn’t weigh it but I would put it in the 18-20 oz range. Maybe if we ask nice HT will weigh it.

-- -Dan

View Hammerthumb's profile (online now)


3055 posts in 2775 days

#11 posted 07-02-2014 04:05 PM

I’ll try to remember to weigh it later, but I can tell you it has some heft!

-- Paul, Duvall, WA

View BigRedKnothead's profile


8574 posts in 2782 days

#12 posted 07-03-2014 01:38 PM

Nice job man. The dye on the hand was worth your effort.

-- "At the end of the day, try and make it beautiful....because the world is full of ugly." Konrad Sauer

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