Introduction: How to Make Your Own "Moose Mallet" (hammer With Chisel Inside)

Picture of How to Make Your Own "Moose Mallet" (hammer With Chisel Inside)

While I didn’t invent this hammer-chisel combination, I did make some minor improvements to it and named it the Moose Mallet.

It is a simple, easy, and cheap way to create a hammer with a neat storage area for a chisel.  Whether you are a scuba wreck diver or a farmer, this is a clever way for you to carry two tools in the same space as one.

Please note, this is my very first Instructable, so please excuses any mistakes.  I also welcome all comments on my Instructable (both good and bad.)

Step 1: What You Need...

Picture of What You Need...

To create a Moose Mallet, you will need the following…
-A steel pipe (I used 1” diameter steel pipe).
This pipe needs to be as long as you want your hammer’s handle to be, and it needs to be treaded at one end.

-A steel hammer head
-End cap for the steel pipe
-Single link of a small chain (optional)

Tools required are…
-Drill with a drill bit slightly bigger than the chisel
-Paint (optional)
-Grip tape (optional)

Step 2: Let's Get Started

Picture of Let's Get Started

OK, from the pictures, this is a pretty easy Instructable to figure out.  So I’ll keep the verbiage to a minimal.

Weld the hammer head to the non-thread side of your pipe.  Make sure it’s centered over the hole that would normally have the handle in it.

*You can also add a small link of chain to the top of the mallet to give you a place to hang the hammer from.*

Now drill a hole in the center of the end cap for the chisel.  Made sure it’s centered.

Place the chisel in the hole so only a little bit of the flat end stands proud of the cap and weld in place.


Step 3: Clean Up the Welds

Picture of Clean Up the Welds

Now take a grinder to the welds to clean them up.  Make sure you have SOLID welds on the hammer head.  You don’t want that flying off when you are swinging this thing.

Also, check the fit of the end cap.

Step 4: Paint and Add the Grip Tape

Picture of Paint and Add the Grip Tape

Ok, so all that is left is putting a coat of paint and a layer of grip tape on the Moose Mallet!

Step 5:

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There is also a quick and easy way to make a handy holder for your new Moose Mallet.
Just take a piece of PVC tubing that is bigger than the OD of the end cap and attach it to the surface that you want to put the Moose Mallet.  I used zip ties here, but you can used anything.

PLEASE NOTE: This instructable is for informational purposes only.  Any damage you do as a result of this information is on you.  If you don’t know what you are doing with a welder, grinder, drill, or even a hammer, then please don’t try to make this item. 


I am in the shed! (author)2012-02-09

Good job, good idea. Don't forget to re-harden the chisel where you welded it or it will be soft.

bowmaster (author)2010-01-22

Cool. I might modify this into a sword cane.

MTummino (author)2009-10-31

Good Job
Where did you get the steel hammer head?

inchman (author)MTummino2010-01-07

I got it from anold hammer that the handle broke on.

Aaronius (author)2009-10-29

Ah! Now that should work!

l8nite (author)2009-10-28

great idea and really nice ible !  For those who might not have a lot of call for a chisel the handle could hold some screw drivers or open end wrenches.

inchman (author)l8nite2009-10-28

That's a great idea!!  In fact, you could have a few different endcaps for different jobs!  HUM...  sounds like I'll be in the shop tonight!

l8nite (author)inchman2009-10-28

 I actually meant just slide the other tools inside the handle (like a survival knife) they might slide around a little but probably not to badly. I think it would  make a great tool for off roaders or campers... now you got me thinking !!! change the hammer for an old shovel head, make the handle longer and store rope, pegs, tools whatever... OR, make a couple, hammer, shovel or whatever and use a coupler to attach them when needed, so one would have the handle,coupler,short nipple, end cap.... hhhmmmmmmmm

berky93 (author)l8nite2009-10-28

I have a hammer that has a flat head screwdriver inside the handle. The hand of that screwdriver is hollow, and inside it is a philips head screwdriver of the same size (but shorter and with a thinner handle) inside the philips head screwdriver is a smaller flat head screwdriver, with another philips head scredriver inside of that. its like 5 tools in one!

although I still prefer my swiss army knife with interchangeable bits, because its also got hex and star bits.

lemonie (author)2009-10-28

If I did this myself I'd be worried about the weld failing under heavy-pailing, do you have an idea as to how much whack you can give it without the head coming off?


inchman (author)lemonie2009-10-28

It hasn't broken yet.   But that will depend on your welding skill.

lemonie (author)inchman2009-10-28

Thanks for the reply - I have no welding skills..


crapflinger (author)2009-10-28

the shock to your hands has to be impressive if you're actually hammering really hard with this thing on that chisel... stil hammer to steel pipe...youch!

Aaronius (author)2009-10-28

Nice Idea. I worry though that the tubing for the holder might slip out of the wire ties.

inchman (author)Aaronius2009-10-28

The wire ties go through holes in the PVC tube.

~Sasquatch~ (author)2009-10-28

It's a clever idea, but as the end-cap is cast iron, ie, "pig metal" , it doesn't weld very well - I wonder how much 'hammering it would take before the shock/impact vibrations cracked your weld?
Perhaps a drilled-thru hole/bolt/rubber washer into the cold chisel might hold up better?
Or mebbe just wrap the chisel in thin expanded-foam-wrap and carry it loose in the handle?

...Just a thought.

inchman (author)~Sasquatch~2009-10-28
You’re right about the end cap material.  That is why it’s important to put the chisel all the way through the cap, so any hammering is directly on the chisel.
I’ve been using this hammer for a while and I’ve known people that used them for decades without a problem.  
I do like the washer idea.  I’ll look into making one with an updated chisel next.

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