Big Darn Mallet

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Project by Kindlingmaker posted 02-17-2009 05:14 AM 3310 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


443 posts in 3764 days

#1 posted 02-17-2009 05:56 AM

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


35186 posts in 4760 days

#2 posted 02-17-2009 07:18 AM

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. Appomattox Virginia [email protected]

View WoodSpanker's profile


560 posts in 3752 days

#3 posted 02-17-2009 10:37 AM

The Hammer of Thor, perhaps? :)

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

View psquared's profile


46 posts in 3865 days

#4 posted 02-17-2009 01:09 PM

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


2658 posts in 3886 days

#5 posted 02-17-2009 03:00 PM

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


173 posts in 4069 days

#6 posted 02-17-2009 04:47 PM

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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