Installing Splitting Mail Handle

Glenn F. · Mar 30, 2017

I am about to install a wooden handle (no fiberglass available for my unit) on my 8# splitting maul. End of handle sticks out of head probably 1.5 inches, and wedge split does not go all the way to the beginning of head. I'll cut off the 1.5 inches, but should I saw the split to go the full distance of the head?

Thanks,
Glenn F.

kcm.MN · Mar 30, 2017

Your split will be fine so long as it goes about 3/4 the distance through the maul head. However, you might need to use more than one wedge. I always keep cheap wood shims on hand. If it ever gets to a point where it won't accept any more wedges yet the head seems a little loose, then I'll add some short wood screws. Have never had one fly off since. ...After awhile, I also started drilling through the head and handle, then adding a roll pin.

golfcartman · Mar 30, 2017

I would only cut the slot for the wedge as deep as the wedge is long. You only want to spread the end of the handle to make it hold.

4wdtom · Mar 30, 2017

After I put in the wood wedge that comes with a lot of handles I then put in a few steel ones that I keep around. You can make steel ones by grinding a taper on a 1/8 or 3/16" thick piece of steel which I sometimes do but mostly I use store bought wedges. Nails work in a pinch but you need more of them. Just drive in whatever you use until it won't go in anymore then cut it off if necessary.

TimV · Mar 30, 2017

Glenn: It only needs to about 2/3 of the way down the head--if you inspect the eye, you should be able to see where the taper ends, and that's the part you've got to fill. I'm attaching the USFS video I've referenced before on hanging axes, but the technique is basically the same for most striking tools. The hanging section is about the first 15 minutes, and it's well worth your time to watch. Whatever method you use, DO NOT resort to dangerous stop-gaps like using wood screws or soaking the head--they're a sure sign of an incompetent job, and if the head is loose enough to warrant using them, it's loose enough to take off and be done over right--the life you save could be your own or a loved one's.
An ax to hang USFS

JDBRIDER · Mar 30, 2017

Be sure to install a rubber handle protector over the handle before you drive the handle into the head. The handle will last lots longer.

2x4 · Mar 31, 2017

after its together, drill a hole completely thru the head & handle, then put a rivet or nail thru & flatten the end so its flush with the head metal. Someday that wedge may come loose & the rivet/nail will save someones life.

2x4 · Mar 31, 2017

handle protector has save me from putting in several handles.

Dusty MI · Mar 31, 2017

After you mark where you need to cut off the extra length and before you cut it, I would use a hack saw to cut the split deeper, or any other saw that is easy cut straight and makes a narrow kerf.

Dusty

Installing Splitting Mail Handle

Glenn F.

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kcm.MN

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golfcartman

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4wdtom

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TimV

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JDBRIDER

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2x4

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2x4

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Dusty MI

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