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A joiners Mallet is a great first tool to make. not only is it an extremely useful tool, but it is a great exercise in skills. this simple project can be made in a day with basic tools, and in this case is made from firewood.

Tools needed. #4 Hand plane setup for smoothing: http://amzn.to/2hc6LQZ

Scrub or foreplane: http://amzn.to/2hUHD0p

Squair: http://amzn.to/2ia9M3Z

Marking Gauge: http://amzn.to/2i0jvHx

Bevel Gauge: http://amzn.to/2i2FoZ8

Frame saw: http://www.blackburntools.com/new-tools/new-saws-...

Panel saw: http://amzn.to/2hjAura

Bevel up Low angle plane: http://amzn.to/2ikc9Sd

Round bottom spokeshave: http://amzn.to/2hZRxvf

Marking knife: http://amzn.to/2hPHf34

Brace: http://amzn.to/2hPEs9Y

Bit set: http://amzn.to/2hZVT5T

Chisel Set: http://amzn.to/2i26mzX

Block Plane: http://amzn.to/2ikkaqg

Supplies used

Oak Firewood: free craigslist, look for dried or something that has been sitting out for a year or more.

Epoxy: Resin http://amzn.to/2hPz06T Hardener http://amzn.to/2inhPa2

Boiled Linseed Oil: http://amzn.to/2hPEUVO

Past Wax: http://amzn.to/2inlN23

Related videos

Frame Saw Build: https://www.youtube.com/watch?v=Z1fEYcxM9Ic

BLO and Past Wax: https://www.youtube.com/watch?v=KvSvmOwmNV8

Paul Sellers Mallet build: https://www.youtube.com/watch?v=u31Ixu6mSHY

Step 1: Flatten the First Side

Chose a piece of firewood that you think you can get a mallet head out of. I like a piece of wood with figure ad that will often make the head last longer but it makes it more difficult to shape. I chose the side that is closest to flat and then use a #5 heavily set hand plane or scrub plane to flatten that one side. This then becomes the reference side that I make all my marks off of.

Step 2: Cut Other 3 Sides

With one side to measure off of, I mark on the end of the firewood the sides to be cut off. My Mallet heat is about 3 ½” high and 3” wide, but you can make it whatever you think looks good. I start by cutting off the two sides 90 degrees to the reference face so that I can follow the line on the reference face with the saw. To cut It I use a Frame saw that I made a while ago here: https://www.youtube.com/watch?v=Z1fEYcxM9Ic but you can use a hand saw it will just take a bit longer.

Step 3: Cut to Length

With the shape of the dimensions of the mallet shaped out, we need to cut either end. I like to cut them at about 5 degrees but again whatever looks good to you. I make the cut with a Crosscut hand saw in the vice of the bench. I draw out the cut lines with a square and bevel gauge.

Step 4: Cut a Handle

You could easily cut a handle out of firewood the same way you cut the head out of the firewood.I used a scrap of White Oak that was ⅞” thick. You want the handle to have a taper. Mine was 15” long the top was 1 ½” wide and the bottom was ¾” so it tapers a total of ¾” from end to end. This will wedge it in the mallet head so that it can not fly off. I made the cut with a rip filed panel saw in the bench vice.

Step 5: Layout the Handle on the Mallet

I use a marking knife to find the center of the handle and the center of the mallet head. Then lay the mallet head on top of the handle so the center lines match up and there is about 1 ½” - 2” of the handle sticking above the head. Next, make a small nick on the other side of the handle at the bottom of the mallet and the top. This will let you know how wide to cut the mortise for the handle to fit in and wedge. Next, with a square carry those lines from the nicks across the top and bottom of the head.then set the mallet on across the head to mark out the second dimension of the mortice.

Step 6: Cut the Mortice

I like to start the cut with a Brace and bit. I chose a bit that is about 1/16” thinner than the mortise and bore out the center of the mortise with that. (this is the boring part) next use a chisel to remove the waste. After taking some out I check the handle to make sure it fits. Then remove more until the handle fits nicely from end to end. You should be left with 1 ½” of the handle sticking up above the head. It should be difficult to drive it in and it should fit very tightly. After a year or so of use it will slide another ½” or so

Step 7: Shape the Head

I like the top of my mallet to look like it is rounded, but you can do whatever you feel like. This is quickly done with a #4 hand plane or spokeshave. For the two ends I use Bevel Up Low angle Jack Plane as it pushes a bit easier. Then just the #4 to smooth the other sides. I also like to put a very heavy chamfer on all edges. This is easily done with a block plane or spokeshave.

Step 8: Shape the Handle

This is a very personal step so everyone has a preferred grip. It is meant to be held up close to the head unlike a hammer. But I just put a chamfer on the 4 corners where my hand connects with it. Then chamfer the edges of the bottom and top.

Step 9: Finish and Assembly

My preferred finish for hand tools is Boiled Linseed Oil and paste wax. One or two coats of BLO then apply a light coat of Paste Wax let it set for 20 mins or so then buff off the excess. I have a whole video on the process here. https://www.youtube.com/watch?v=KvSvmOwmNV8

<p>in germany they used to give a gunsmith trainee a chunk of metal and a file and his firs job was to make his tools. as a concept its hard to beat, and the result is impressive here.-makes me think of Leroy Jethro Gibbs building boats in the basenment, bravo.</p>
oh ya. Most of my tools are self-made. the best tools in the shop are the ones you make yourself!
Excellent job!
thanks man!<br>
Beautiful mallet. I have been meaning to make one of these for my shop. You have inspired me to get to work. Also, it turns out we're neighbors... I'm in poplar grove.
Verry cool! I am looking forward to seeing what you make. I have been wanting to do a Wood by Wright hang out one of these days. would love to meet you.
<p>Its remarkable :)</p>
thank you!
Nice work, I have never come across a frame saw, very interesting.
Thanks. One of my favorite traditional saws. so much fun to make and use!

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Bio: I have been working with wood since I could stumble into the shop with my dad. About a year ago I moved into a house ... More »
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