Maple and Cherry Chisel Mallet

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Project by OttawaBourbon posted 08-31-2016 12:15 PM 4107 views 8 times favorited 7 comments Add to Favorites Watch

I found this mallet on LJ ( and got inspired to give it a go.

My mallet is made of hard maple and cherry and has final dimensions of approx. 11 inches long with the head measuring ~5×2.25×2.25.

Step 1: The Handle
The handle was ripped on the table saw from a piece of hard maple to 1.5×0.75×11inches. Once done, I took out a combination square and started marking it up with a pencil to get the shape I wanted. Once done, it was off to the bandsaw for the cuts. Slots were also cut into the top portion to accommodate two cherry wedges. My kijiji budget-bandsaw doesn’t like cutting straight but with a bit of patience, it turned out decently. In the future, I’d probably cut the slots with a table saw to make sure they came out straighter. I had issues with my wedges (also cut on the bandsaw). Some sanding was done at this point to shape the top of the head.

Step 2: The Head
Two slices of cherry and one of maple (0.75×5.5×2.25) were cut on the table saw using the fence and a sled. The cherry slices were put to the side and I then traced the handle outline in the centre of the maple piece. I then cut the maple into two pieces to fit the handle between them. An arch was also cut across the top of all pieces as well as a slight taper on both faces to give it its shape. After this was done, I glued it all up in two stages. Pro-tip: Take your time banging in the wedges! I was a bit too rough and I broke one and had to scramble to make another while everything was gluing up. Spending more time getting my slots straight would have prevented this. Luckily, it worked out.

Step 3: Pommel and Sanding
I really liked the idea of a pommel at the base and the two-tone in WhoMe’s mallet. So, I glued some 3/8 pieces of cherry to the base of the handle. These were then shaped with the sander along with the rest of the handle and head. Once the sanding was done, a hole was added at the base of the handle using a 5/8 forstner bit to finish the piece. Everything was then finished with two coats of Clapham’s beeswax & linseed oil mix.

7 comments so far

View doubleDD's profile


11290 posts in 3503 days

#1 posted 08-31-2016 01:26 PM

Well done on the mallet. These can be addictive.

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

View johnstoneb's profile


3220 posts in 3632 days

#2 posted 08-31-2016 01:42 PM

Like your wood selection. They can definitely be addicting be carefull.

-- Bruce, Boise, ID

View OttawaBourbon's profile


6 posts in 2095 days

#3 posted 08-31-2016 02:34 PM

Thanks guys. You aren’t kidding. It’s the first tool I’ve made and used on another project (I’m working on a chiseled sign right now). So I’m now looking at other hand tools that I could make. Any suggestions would be welcome :)

View WhoMe's profile


1568 posts in 4703 days

#4 posted 08-31-2016 07:47 PM

Nice job. You will find all kinds of uses for your new mallet. Ive used the heck out of my mallet since I made that one a few years ago. It is still holding up really well. About 3 months ago, I made another, slightly smaller, out of a bubinga core and yelloheart sides. It looks really nice and the bubinga is really hard, the yelloheart, not as hard as I had hoped. I have yet to post it in my projects. I did post it with the krenov style plane I made out of the same woods. I think out was on the hand plane thread.
You might find as I did that the blo really yellows the maple over time.

-- I'm not clumsy.. It's just the floor hates me, the tables and chairs are bullies, the wall gets in the way AAANNNDDD table saws BITE my fingers!!!.. - Mike -

View OttawaBourbon's profile


6 posts in 2095 days

#5 posted 09-01-2016 10:24 AM

Thanks Mike. I’ll keep that in mind for the blo and see how it changes with age. It’s my first time using it and I’m really pleased with the finish right now.


View JPJ's profile


821 posts in 4080 days

#6 posted 09-07-2016 03:30 AM

Nice job!

View JPJ's profile


821 posts in 4080 days

#7 posted 09-07-2016 03:32 AM

Nice job!

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