Walnut and Birdseye Mallet

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Project by Luke posted 02-13-2015 05:35 AM 1524 views 2 times favorited 2 comments Add to Favorites Watch

After watching Roy Underhill mortise out a mallet in 20 min on his “Big Ash Mallet” I decided to give it a try. I had some scrap 8/4 walnut and a cutoff of some Birdseye maple just perfect for a handle.

I cut the mallet to what seemed like a good size and mortised out the wedge shape mortise using a rusty bit brace I got at an antique shop for $5. (On my list of hand tools to restore.). Then chopped out the waste using a chsel and a plastic mallet. It was here I realy could have used this mallet to make the mallet.

I chamfered the edges and used a piece of leather I had. I stretched the otherwise too short price of leather by greasing it with water and oil. A trick I saw on myth busters. It made that small strip almost twice the length.

The mallet was finished with a few coats of BLO. It weighs in at 15.5 oz. feels great in the hand.

2 comments so far

View doubleDD's profile


8661 posts in 2555 days

#1 posted 02-13-2015 02:01 PM

That is a great looking mallet. The walnut and maple are a good combo.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View R_Stad's profile


426 posts in 2355 days

#2 posted 02-13-2015 03:46 PM

Sweet mallet. Well done Luke.

-- Rod - Oregon

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