Woodworking on a Half-Shoestring #85: Joiners Mallet

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Blog entry by retired_guru posted 11-23-2016 12:03 AM 1672 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 84: Harbor Freight's DrillMaster 2 HP Fixed Base Router Fix Part 85 of Woodworking on a Half-Shoestring series Part 86: Repair Broken Handle on Antique Rolling Pin »

I’ve been wanting a larger mallet for chisel work, but until now didn’t have a large enough piece of hardwood. The head is oak, part of a pallet runner I acquired in the summer. The handle was make from a section of an old, discarded TruValue snow shovel handle; probably ash. I mounted the handle in my lathe and reduced the section that will fit into the 1” hole made in the head. The faces have a 2 degree rake toward the handle. Some subtle work was done on the rest of the handle for a more comfortable grip. Epoxy was used to glue the tight-fitting handle to the head. One coat of Danish oil for the finish.

Update: A day later, I got a chance to find out if the mallet was going to be an asset in the shop. I clamped down a thin scrap of poplar and chopped a square through-mortise the width of a Harbor Freight chisel that was sharp enough to cut you, but not able to shave the hairs off your arm. The mallet worked better than I had hoped for.

I was surprised at what little effort I had to put into each swing. I wasn’t sure the mallet had enough weight for chopping out mortises. Remember, not the sharpest chisel in the lot. ;)

“My kingdom for a tenon!”

“No pain, all gain.” Works well enough for what I can do. Passed! (My first truly useful mallet!)

-- -- Paul: jack of all dreams, a master none.

4 comments so far

View luv2learn's profile


3066 posts in 3083 days

#1 posted 11-23-2016 12:17 AM

Nice combination of scrap materials Paul. I like your re-purposed mallet.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View ralbuck's profile


6547 posts in 3047 days

#2 posted 11-23-2016 01:06 AM

I relly like that you spared no expense in the build!

Most of my projects are made that way too. Fire wood and scraps are my lumber yard!

GREAT usable tool!

-- Wood rescue is good for the environment and me! just rjR

View retired_guru's profile


838 posts in 2140 days

#3 posted 11-23-2016 03:47 AM

Thanks, Lee. You know me: waste not, want not. :)

-- -- Paul: jack of all dreams, a master none.

View retired_guru's profile


838 posts in 2140 days

#4 posted 11-23-2016 03:48 AM

Ha! Thanks, rjR. No castout is too good for my projects. :D

-- -- Paul: jack of all dreams, a master none.

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