Heavy ash chisel mallet

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Project by jason posted 09-25-2009 04:50 AM 2999 views 1 time favorited 8 comments Add to Favorites Watch

Hello again out there in woodland. I needed a nice heavy mallet for a couple new ray iles mortise chisels I aquired. After seeing what was avaliable through the local wood stores I decided I just needed to build my own. I chopped the mortise in this by hand with the chisel you see here. I’ll tell you what I learned, I dont want to chop a whole lot of 3 1/2” deep holes. For the handle I cut the tenon first, then I cut out the rough shape on the bandsaw. For the final shaping I used my trusty #50 wood rasp, then a little sandpaper. To hold the tenon in place I cut a saw kerf along the width of the tenon and drove in a wedge about an inch deep. Works like a charm. I think it looks pretty good. Should make those mortise chisels work a lot faster. thanks for looking.

8 comments so far

View Karson's profile


35209 posts in 4961 days

#1 posted 09-25-2009 04:53 AM

Great looking mallet. Sorry you didn’t have a mallet to chop the mortises in the mallet.

-- 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 BTKS's profile


1989 posts in 4025 days

#2 posted 09-25-2009 04:54 AM

Really nice work.

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View jason's profile


33 posts in 3935 days

#3 posted 09-25-2009 05:23 AM

I did use a mallet, it was just a little one.

View Jeremy Hill's profile

Jeremy Hill

16 posts in 3751 days

#4 posted 09-25-2009 07:02 AM

That’s sweet! How big is it? I’m gonna have to make one for myself.

-- Jeremy Hill

View threehands's profile


29 posts in 3734 days

#5 posted 09-25-2009 11:27 AM

Very nice work. You should start to make the chisel now. Look at damascus steel

-- Three Hands- It's better to burn out..than to fade away. Stonecutter, copper, Offical putzer, proprieter of not making a profit (non-profit) woodworking shop, and possibly mental wizard

View huff's profile


2828 posts in 3846 days

#6 posted 09-26-2009 04:05 AM

Great job on your mallet Looks like it would be very comfortable to use.

-- John @

View knapster's profile


39 posts in 4036 days

#7 posted 09-26-2009 08:40 PM

a handy tool that will see plenty of use in the future i’m sure!

-- jk

View Cantputjamontoast's profile


416 posts in 3993 days

#8 posted 09-30-2009 02:13 AM

that’s a nice mallet

-- "Not skilled enough to wipe jam on toast!"

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