Tuesday, June 19, 2018

Replacing a Broken Handle on a Sledge Hammer or Mallet

A while back I wrote a post about changing a broken handle on a shovel and how easy it was to do.  Today we replaced a broken wood handle on a small sledge hammer/mallet.  It is just as easy but it is a different procedure.
We were in the middle of something when R asked me to go get the small mallet.  It was then that I got a good look at the condition it was in and it was bad.  A big chunk of wood was missing and R had added a small deck screw to hold it together.
I had a 5 dollar off a $25 purchase at Ace Hardware so I asked him if there was something else we needed to make the $25 requirement.  R pulled out another shovel that needed a handle so that was enough for me to use the coupon. Make sure to take your mallet with you so that you buy the correct handle.

The shovel handle was $14.95 and the small mallet or hammer handle was $5.59  so I still needed around 5 bucks so I bought a couple of Japanese beetle attractant which brought the total to $32.56 then minus 5 bucks for a total of $29.21.
First off, before you head to the cash register with your new handle make sure that the little metal shim is taped to the new handle.
Here is the top of the old handle (the oval area) and you will need to use a drill bit to remove some of the wood so that the old wood handle can then be pushed out using a punch. 
It is easier if you use a work mate style table to hold the mallet in place while you drill and then use the punch and a hammer to push the old handle out.  You can also clamp the mallet head in a vise.  Don't clamp on the handle because you want the handle to fall out when you use the center punch.
Use the center punch to push the old wood handle out of the mallet head.
Test fit the handle.  You will probably see that it is too big.  Now is not the time to rush this part.  Sand a little off the edges on the very end.  R likes to use his belt sander placed upside down and clamped in the workmate.
Keep testing and sanding.
Always wear safety glasses or cheap sunglasses... LOL.  Wearing them tucked onto the neck of your t shirt will do nothing for the protection of your eyes.
Getting close but not close enough.
See the dirt?  That is where it is rubbing and will give you an idea where to sand.

We might be close.
Now you can insert the shim into the factory cut slit in the handle.
Insert the small end of the shim into the slit.
Yes, that is a can of cat food.  It was the only way to keep Morrie from jumping up on the workmate to see what was going on.  He is so nosy and not in the least scared of noisy tools. 
Use a chisel to countersink the shim and you are done.

A new handle for $5.59 is much less expensive than buying a new hammer.  Plus, as my husband says, there is nothing like old tools.

Tools needed

Drill motor and drill bit
Sandpaper or sander
Center punch
Clamping device like work mate or vise
Safety glasses

Reuse Repurpose Recycle

Don't forget to follow Gear Acres on


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