Wooden mallet DIY

Wooden mallet DIY

In the previous posts we saw how to cut a wooden dowel with the table jigsaw and how to cut a shroud with the column drill. So in this post I am going to use the two pieces in which I cut the tenon and the mortise to make a wooden mace joining them together and shaping them.

You will see that I use a small drum sander for column drill. Now i have a homemade sanding drum which I made myself for the drill press.

Draw the desired shape on the wooden handle

I'm going to start by drawing a simple shape on the wooden handle. I just want to narrow this piece of wood a bit to make it easier to grip. And by the way make it more beautiful.


Cut the shape of the wooden handle

And once I have the drawing I want, I cut the shape of the handle with my table jigsaw.

Sanding cylinder for sanding and finishing curves

The curved cuts are quite rough, but with the sanding cylinder it is very easy to leave them decent. And I'm also going to take advantage of the sanding cylinder attached to the column drill to sand the straight cuts of the handle.

Round the corners of the handle

So now I can use the table router, with a ball-bearing rounding cutter, to round the corners of the shank ...

Strawberry to round the corners of the club head

and to round the corners of the clubhead.

Strawberry leaves a step in the hub

Actually, the bur I use to round the corners of the clubhead has a larger diameter than the bur I used to round the corners of the handle. And at some point I had to change the bearing, since it has a somewhat smaller one than it should. The result is a small jump in the wood that luckily suits him quite well.

Draw the shape of the handle on the head

The bad thing is that with that step the handle does not fit well against the head, so I have a drawing of the shape of the handle of the mace in contact with the head ...

Cut a recess to adjust the handle joint

and I'm going to use a chisel to make a recess in the shape of that part of the handle. In addition, I also use the sanding cylinder with the drill press to sand and shape that part of the handle (as seen in the video). Thus the transition from the handle to the head of the wooden club is better.

Glue the wooden dowel into the mortise

Now after gluing the mortise and tenon joint, and waiting for the carpenter's glue to be completely dry,

Use the sanding cylinder to shape the mortise-tenon joint

I am going to use the sanding cylinder to shape the top of the wooden club. Thus the visible part of the spike is also slightly rounded.

Retouch the hub head with the router

Now I just have to go back to the milling table to round the corners of the area that I just sanded with the sanding cylinder and give continuity to the small step that I have.

Sanding the wooden mallet

And finally I can sand the entire wooden club well and apply a couple of coats of varnish.

The result is a pretty pretty mace that will serve as decoration. Although it may also serve to break some nuts or other nuts, but not to hit the chisels in my small carpentry workshop.


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2 comments on "How to make a wooden mace"

    1. Enredando No Garaxe

      Because it has very little weight. To hit the chisels it is good that the head of the club has a little weight

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