Introduction: Monster Maul

Picture of Monster Maul

Hi Instructables community, I would like to share my Monster Maul project I just completed. Most splitting mauls sold have either 6 or 8 lbs heads on them. This monster maul I created has a 20.4 lbs head! Perhaps a bit of a novelty, but it is still swingable and certainly has the power to get through the toughest of logs. So here is my Instructable from concept to completion.

Step 1: Concept

Picture of Concept

I kind of always wanted to build an oversized splitting maul, but really didn't know how to do it until I saw this large 'fence post' maul at the local hardware store. Shopping around in the same store I also found these wood wedges, that when combined should create the correct angle and length needed to make a functional oversized splitting maul.

Step 2: Welding Wedge

Picture of Welding Wedge

In order to create the main wedge, the three smaller wedges needed to be welded together. I grinded and prepared the welding surfaces, then welded as deeply as my little welder could go. TIP: Preheating the metal helps a lot if your welder is under powered.

Step 3: Grinding, Cutting and Pinning

Picture of Grinding, Cutting and Pinning

I then grinded the welds down to form a unified wedge, then cut the wedge to a length I thought was appropriate. Knowing that my welder is a little under powered and that I wanted to grind the welds down anyways, I wanted some extra reassurance that the wedge wasn't going to fall off and hurt anyone when they were swinging this behemoth. So I decided to drill pins in joining the two sections. I bashed the pins with a framing hammer to create a tight fit.

Step 4: Welding It Together

Picture of Welding It Together

After I drilled out the pin holes in the main body and hammered the two pieces together, I needed to welded them. But before I did this, I needed to preheat the metal in order for my little welder to get enough penetration into these two large pieces of metal. So I preheated the metal using my BBQ on max (700F it said). The welding went well. Next was grinding the welds smooth using various flapper wheels.

Step 5: Painting

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A couple coats of Tremclad black gloss

Step 6: Gluing

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The head is normally a friction fit, but I wanted extra reassurance that it wasn't going to move, so I glued it on using construction adhesive.

Step 7: Handle Guard

Picture of Handle Guard

Most splitting mauls are subject to handle damage or breakage, and it certainly was a big concern with the monster maul. So what I choose to do was a carbon fiber wrap and Kevlar banding for protection. It looks good and feels super solid.

Step 8: Final Product

Picture of Final Product

I'm really happy with the way this project turned out. I just finished it today and haven't had a chance to test it yet, plus I don't have any wood to cut at the moment. I'm looking forward to testing it during the summer and to see what it's capable of splitting. I think the unique shape of it might have some benefits. Like having a smaller cutting blade with a considerable mass behind it. Also having a flat lip where the wedge is welded to the hammer might prevent the monster maul from passing straight through the wood block, which actually might be a good thing for such a heavy splitting maul. If it turns out to be a hindrance I can easily modify it.

Anyways it was a fun project, and am glad to share it with the Instructables community:)


sic6sic (author)2017-03-13

as someone who has used a wood burning stove for heat for many years, this would be a godsend for some of the more gnarled and massive stumps. thank you for outlining the process. im going to look into making this for my stepdad over the summer.

DIY Hacks and How Tos (author)2017-03-12

Awesome! I want to make one.

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