Make Your Own 16th-17th Century Ottoman-Style Mace (Beginner-Friendly)

Ever wanted to hold a piece of history in your hand—something straight off a battlefield and a royal court? In this guide, you’ll build your own Ottoman-style mace, inspired by the 16th–17th century bozdoğan. No forge, no experience—just simple tools and a beginner-friendly approach.

Perfect for display, cosplay, or just because it looks awesome, this build captures the bold, armor-crushing design that once symbolized power and leadership. Ready to make something striking, unique, and seriously cool? Let’s get started.

Materials

●Wood (Imbuia or similar hardwood)

●Old gear (from a drivetrain/gearbox )

●Copper pipe (scrap piece)

●Eyebolt (only item you’ll likely need to buy)

Tools

●Wood clamp

●Skill saw (or saw you prefer)

●Angle grinder

●40-grit sanding/flap disc (for grinder)

●Wood hand saw

●Pen or marker

●60 cm ruler (or measuring tape)

●Old cloth

●Cordless drill

●Drill bit (same size as eye bolt thread)

●Hacksaw

Start with your piece of wood. I used repurposed Imbuia hardwood from a old project.

Measure and cut a 4 cm x 4 cm thick and 38cm in length section for the handle.

Clamp the wood securely and use a skill saw (or whatever cutting tool you have availble) to cut it to size.

Take your gear and place it on top of the handle.

Use a pen to mark where the gear will sit this will guide your cutting in the next step.

Clamp the wood again and use a hand saw to cut out the rough shape based on your markings.

Tip: Cut slightly outside your marked lines. This ensures a tight fit. A bit tighter fit is better than too loose fit.

Gently tap the shaped wooden neck into the gear.

Go slow—use controlled taps so you don’t damage the gear. If needed, use wooden blocks to distribute force evenly.

Use the ruler(measuring tape) measure a ~2.5 cm length piece of copper pipe and using a hacksaw cut the piece.

Insert it into the top of the joint and gently hammer it in to act as a wedge with the hammer of your choice.

Then use the wood saw to trim the wood or hack saw to cut the excess off. Then use the angle grinder and 40 gritt flap disk to smooth it out.

Important:

When inserting the copper pipe wedge. Tap lightly and move in a circular pattern to avoid bending or warping the pipe.

Now for the fun part.

Use an angle grinder with a 40-grit flap disc to shape the handle so it fits comfortably in your hand.

You can use other tools if you prefer, but i used the grinder as it makes quick work of it.

Drill a hole into the bottom of the handle.

Make sure the drill bit is the same size than the eyebolt thread for a snug fit.

Twist the eyebolt in by hand.

If it’s too long, trim it down with an angle grinder or you can use a hack saw.

Use the angle grinder to carve shallow grooves around the handle. I carved rough grooves for that midevil look.

This improves grip and gives the mace a more finished, tactical look.

Apply your preferred wood sealant.

I used linseed oil—easy to find and gives a great natural finish.

I Used an old cloth to rub it into the wood evenly.

You’ve just turned scrap into something seriously cool.

This build is simple, customizable, and a great way to practice shaping, fitting, and finishing techniques. Plus… it just looks awesome.