8 Jarrah Mallets

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Project by robscastle posted 09-26-2014 11:51 PM 2410 views 1 time favorited 12 comments Add to Favorites Watch

I raided my recycled jarrah pile and decided to make some more mallets, eight in fact.
This is the story.

The timber was inspected and prepared in the usual way jointing and squaring then cutting to size.
I used a roundover bit with a handle template to reproduce the handles.
The heads were prepared with a forstner bit and the wedges from offcut scraps.

I then numbered the handles and sanded them to fit the corresponding number heads.
They were a very good fit and really didnt need a wedge, however I fitted them with wedges to maintain the authenticity.
The handles and wedges are glued in with Titebond III.

Sanding at 180 grit commenced to remove machine marks nicks etc.
Once this was OK I then used 320 grit
Gave them a good blow down with air and applied a wet cloth all over to raise the grain
Another 320 Grit finish, then on to the flap disk its 120 grit but it produced a sililar finish to about 400?
Then a good rub up with steel wool.
I used white compound and a calico woven cloth, the polishing disclosed a few clinkers, so these were rectified and some spot repolishing occured.
Next was a wipe down with a soft cloth to remove any residue accessable, inspection and photo session on top of the stock pile.

Application: So what on earth am I going to do with eight ornamental Mallets?

Well my wife has blessed one already, So I must remember not to challenge her about credit card spendings!!
I will attempt to give my four sons one each under the guise of a kids toy or such!!

Otherwise their off “Straight to the pool room”

You would think they would all be the same but each has its unique characterstic feature.

A question, Do you think a finishing product should be applied, ie shellac wax etc?
The polishing and Sanding setup:


-- Regards Rob

12 comments so far

View Mean_Dean's profile


7057 posts in 4262 days

#1 posted 09-27-2014 12:00 AM

Great looking set of mallets!

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

View David Dean's profile

David Dean

608 posts in 4014 days

#2 posted 09-27-2014 01:02 AM

nice work.

View BobWemm's profile


2985 posts in 3041 days

#3 posted 09-27-2014 01:32 AM

OK Rob, one in each hand, what are you going to do with the other 4.
They look great.


-- 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 notajoiner's profile


5 posts in 2454 days

#4 posted 09-27-2014 01:32 AM

Very nice mallets! But the term “recycled jarrah” implies that someone threw out jarrah in the first place—a crime if there ever was one! :)

-- Embrace imperfection.

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5167 days

#5 posted 09-27-2014 03:32 AM

COOL little mallets…

I like them…

Very nice!

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

View robscastle's profile


7948 posts in 3319 days

#6 posted 09-27-2014 04:17 AM

Thanks Guys,

I enjoyed rescuing the timber and then being able to make something “usefull” from it.

-- Regards Rob

View stefang's profile


17040 posts in 4449 days

#7 posted 09-27-2014 12:12 PM

They all look great Robert. I would suggest you at least finish the handles with a hard finish as they can get pretty grubby otherwise. You can use non-shiny poly for that if you want to keep the natural look.

-- Mike, an American living in Norway.

View Phil Clark's profile

Phil Clark

359 posts in 4910 days

#8 posted 09-27-2014 01:41 PM

Robert a question about Jarrah, if I may. Just this week I have been cutting Jarrah flooring milled more than a century ago and found the dust quite irritating – quickly put on my dust mask. Is this characteristic with Jarrah? I’m using the Jarrrah in my first attempts at Lew’s french rolling pins.

-- Legacy Woodcraft

View helluvawreck's profile


32122 posts in 3981 days

#9 posted 09-27-2014 01:47 PM

Nice set of mallets. They’ll also make great gifts.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View robscastle's profile


7948 posts in 3319 days

#10 posted 09-27-2014 09:22 PM


Yes Jarrah dust is a mild irritant to both eyes and lungs.

Its not particularly in the high risk catagory but as with all dust regardless of its origin not good for the eyes and lungs.
I think your dust mask solution will provide adequate protection and allow you to work safely and without undue concern.

I do all my work outdoors use and extractor and meticlously clean up after I have finished mainly out out of good work practice.

You may benefit using a dust extraction on the saw.

You probaly already know Jarrah is very tough on tool edges and bluntens them at a higher percentage than other timbers.

The use of Jarrah for flooring these days is almost cost prohibitive so guard your supply well!

It certainly would not be recommended for replacing deckboards on potato crates these days for the same reason, plus I would doubt if its even available.

-- Regards Rob

View Roger's profile


21054 posts in 3919 days

#11 posted 10-01-2014 12:38 PM

Very nice attitude/micro-adjusting tools.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View robscastle's profile


7948 posts in 3319 days

#12 posted 04-27-2018 06:16 AM

All gone cleverly distributed amoungst family members I think Aurora still has one under her pillow!

-- Regards Rob

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