I recently crafted my first mallet using a wedged tenon design. The mallet head is constructed from three laminated pieces of red oak, and I oriented the grain towards the striking edge. I also made a tenon with slits for wedges to enhance stability. However, I realized after the fact that both the handle and wedges are aligned with the grain facing the striking side. Should I have positioned the handle or wedges across the grain for better durability, or is it mostly just a matter of aesthetics?
2 Answers
In the woodworking program I volunteer with, we actually started a similar project recently. When you mention the grain facing the striking edge, I’d clarify that ideally, the mallet faces should be end grain while the pieces are laminated face grain to face grain. For those wedges, they definitely need to go across the grain instead of aligning with it for better strength.
I built mine with a different approach using an angled through mortise in the head that accommodates a tapered handle. You just drop the handle in, give it a few taps, and it's secure without needing extra wedges—it’s definitely foolproof!
That sounds like a solid method! I'm still getting the hang of angled cuts, but I’ve just started using a spokeshave, so I might try that on my next mallet.