Learning, Hammer,

How to Make a Power Hammer (10-Step DIY Guide)

In today’s article, I’ll teach all you DIYers how to make a power hammer.

A power hammer is a mammoth of a device to save you energy on hammering. But buying a power hammer can be expensive, and you might not get the exact design and power you want. I would say making one by yourself is an advanced but great alternative.

Below ill teach you to make a power hammer through the following steps:

  • Gather the necessary tools.
  • Prepare a plan for the power hammer.
  • Wear safety gear.
  • Build the hammer frame.
  • Build the hammer base.
  • Prepare the pulley assembly.
  • Connect the pulley assembly to the frame.
  • Prepare the hammerhead.
  • Connect the hammerhead to the frame.
  • Connect the motor.

Continue reading the below step-by-step guide for more details.

10-Step Guide to Make a Power Hammer

Important: Even though this homemade power hammer-making process seems straightforward, it is a time-consuming and energy-draining task. And it requires some level of skill. So, if you aren’t comfortable with this process, get help from a professional.

Step 1 – Gather the Necessary Things

First and foremost, gather the following things.

  • Angle grinder
  • Arc welder
  • Few welding rods
  • Stationary drill
  • Power drill
  • Few drill bits
  • Ratchet
  • 2-by-2 inch 5mm angle bar
  • 10-inch diameter thick steel plate (10mm thickness)
  • 5mm thick steel plate
  • 8-inch pulley
  • Motorcycle shock spring
  • Steel rod, 2-foot long and 2-inch diameter
  • Induction motor
  • 1-inch steel rod
  • ¾ inch shafting
  • Two P205 pillow block bearings
  • Two P004 pillow block bearings
  • Two P211 pillow block bearings
  • Different types of nuts and bolts (type and size might change according to what you are building)
  • Few clamps
  • Measuring tape
  • Steel ruler
  • A rubber belt
  • Claw hammer
  • Marker pen
  • Plans for power hammer

After gathering all the things, move on to the next step.

Step 2 – Prepare a Plan for the Power Hammer

Preparing or finding a plan for the power hammer can be challenging for most people. In truth, You can create your plan if you are skilled enough, but if not, we have some alternatives.

pulley assembly for making a hammer
Video | Sek Austria

For instance, this is the completed power hammer (check the image above). In this plan, I placed the motor at the 3 feet mark and the hammerhead (2-inch steel rod) just under 4 feet. The pulley assembly is at the top of the frame, and the striking plate is around 2 feet. The hammer frame is an A-frame. It is a simple design that you can pull out easily at your home.

Also, in this guide, I’m not going to give you any specific lengths and heights; you can change the length and height according to your needs.

Step 3 – Wear Safety Gear

Before starting the power hammer-making process, it is essential to wear the necessary safety gear.

  • Wear rubber gloves to protect your hands.
  • Wear safety glasses to protect your eyes while cutting steel items.
  • Remember to wear a welding helmet during the welding process.
  • Wear safety shoes to protect yourself from electrical shock.

Quick Tip: You are dealing with lots of metals and electricity here. Hence, electrical shock is a genuine concern in this process.

Step 4 – Build the Frame

When making a power hammer, building the frame should be done first. Apply this method to any type of power hammer you are building. Also, you’ll need two identical frames for this.

Take the 2-by-2 angle bar and cut the bar according to the height and shape of the frame. Use the angle grinder for this.

mock up the frame on the table
Video | Sek Austria

Then, grab the pieces on the table and mock up the frame.

clamp the parts to the table
Video | Sek Austria

After creating the shape on the table, clamp the parts to the table.

clamping the parts to the table
Video | Sek Austria

welding the first hammer frame
Video | Sek Austria

Next, take the arc welder and weld the first hammer frame.

Then, repeat the same process and build the second hammer frame.

Quick Tip: Remember to be careful while cutting the angle bar. The above two frames should be identical (As much as possible).

angle bar as frame
Video | Sek Austria

welding the first hammer frame
Video | Sek Austria

Place the completed two frames together like in the above images and weld them.

Step 5 – Built the Base

striking plate
Video | Sek Austria

Now, you can build the base of the power hammer. For this, use a 2-by-2 angle bar and create a rectangular-shaped base frame. Use the grinder to cut the angle bar and arc welder for the welding process.

welding the A-frame on top of the base
Video | Sek Austria

Then, place the A-frame on top of the base and weld them together.

Step 6 – Prepare the Pulley Assembly

Then, take the 10mm thick steel plate and cut a 10-inch diameter disk. A powerful enough grinder can cut disk shape plates without any trouble.

marking the center of the plate
Video | Sek Austria

After that, mark the center of the plate.

placing the plate on the stationary drill
Video | Sek Austria

Place the plate on the stationary drill and drill a hole for a 1-inch steel rod. This hole should be at the center of the disk.

drilling another hole near the center hole
Video | Sek Austria

Next, drill another hole near the center hole. The second hole is used for ¾ inch shafting.

connecting the steel rod to the disk

Connect the 1-inch steel rod to the disk and weld them properly.

welding the ¾-inch shafting
Video | Sek Austria

Then, take ¾-inch shafting and weld it to the second hole.

Tip of the Day: The shafting is used to rotate the power hammer.

inserting one P205 pillow block bearing
Video | Sek Austria

Now insert one P205 pillow block bearing into the welded center steel rod. The bearing should be close to the steel plate.

Then, insert the 8-inch pulley. And finally, insert the second P205 pillow block bearing to the edge of the steel rod. Don’t forget to insert the rubber belt into the pulley.

Step 7 – Connect the Pulley to the Frame

connecting the pulley to the frame
Video | Sek Austria

Next, place the pulley assembly on top of the hammer frame. Mark the locations of the block bearing’s holes.

drilling the four holes
Video | Sek Austria

Then, drill the four holes and connect the assembly to the frame with suitable-sized nuts and bolts. Rotate the assembly a few times using the shafting.

placing the rubber belt on the pulley assembly
Video | Sek Austria

Quick Tip: You should place the rubber belt on the pulley assembly before tightening the nuts.

Step 8 – Prepare the Hammerhead

Now you can start building the hammerhead.

taking the 5mm steel plate
Video | Sek Austria

First, take the 5mm steel plate and draw the above-shown shape.

start building the hammerhead
Video | Sek Austria

Then, clamp the plate to the table and cut the shape using the angle grinder.

4 cut steel plate
Video | Sek Austria

You’ll need at least four of these shapes. So, make sure to arrange them. If needed, smooth the edges using the grinder.

clamping all four pieces of steel plate together
Video | Sek Austria

Clamp all four pieces together. Place them on the stationary drill. Drill a hole in each corner.

connecting steel plates using nuts and bolts
Video | Sek Austria

Now, take two pieces and connect them using nuts and bolts. Tighten the connection using the ratchet.

welding the steel plate to the support piece
Video | Sek Austria

Take two small pieces from the steel plate and weld them to the created support piece.

connecting the small pipe piece
Video | Sek Austria

And connect the small pipe piece as shown in the image.

Do the same for the other two pieces.

motorcycle shock spring
Video | Sek Austria

And connect the two parts to the motorcycle shock spring and the P004 pillow block bearings.

P004 pillow block bearings
Video | Sek Austria

Assemble the two P004 pillow block bearings as shown in the above images (before connecting). 

making another support piece
Video | Sek Austria

Next, make another support piece, as shown in the image.

connect support piece to 2-inch-thick steel rod
Video | Sek Austria

Then, take the 2-inch-thick steel rod (hammerhead) and connect it to the support piece.

connecting the 2-inch steel rod to the shock spring
Video | Sek Austria

Connect the 2-inch steel rod to the shock spring (check the image). You might need some help to connect these parts correctly.

Now, your hammerhead is ready.

Step 9 – Connect the Hammerhead to the Frame

After making the hammerhead, you can now connect it to the frame.

P211 pillow block bearings
Video | Sek Austria

But first, place the two P211 pillow block bearings on the two edges of the hammerhead rod.

connecting the pulley assembly's shafting to the P004 bearing
Video | Sek Austria

Then, connect the pulley assembly’s shafting to the P004 bearing, which is located at the top of the shock spring. If you follow the above process correctly, the P004 bearing hole should match the shafting. Next, connect the two P211 bearings to the power hammer frame.

Step 10 – Connect the Motor

To place the motor, you’ll have to make a platform. So, grab some steel plates and weld them into the frame.

placing the motor and connect the rubber belt
Video | Sek Austria

Place the motor on the platform and connect the rubber belt to it.

connecting the motor to the frame using a steel rod
Video | Sek Austria

Then, connect the motor to the frame using a steel rod. As you can see, the steel rod is connected to the bottom of the frame.

striking plate
Video | Sek Austria

Finally, place the striking plate just below the hammerhead.

Quick Tip: If you have the time and resources, make sure to paint a newly constructed power hammer.

painting the exterior with anti-corrosive paint
Video | Sek Austria

Use anti-corrosive paint and any other paint for the exterior. Supply the power to the motor and check the power hammer.

Important: If the above 10-step guide is confusing to you, please check out the full video tutorial here.

Few Other Ways to Make Power Hammer

Apart from the above 10-step guide, there are many different approaches to making a power hammer.

In this section, I’ll give you a short explanation of those power hammers.

DIY Pneumatic Power Hammer

If you want to make a pneumatic power hammer, you’ll need the following parts.

  • A cylinder
  • Cylinder cushion
  • Foot pedal
  • Plastic exhaust silencers
  • Quick exhaust valves

Homemade Power Hammer

This power hammer runs using a treadmill motor. Finding a treadmill motor is a little tricky. And the same goes for the other parts that need for this process.

However, you can start the process by making the base. Then, weld the other parts into the base. Finally, connect the motor.

Drill-Powered Hammer

Drill powered hammer is one of the coolest power hammers you can make. After all, this is a budget-friendly way to make a power hammer. Here are some of the things you’ll need for this process.

  • Drill
  • Wood
  • Nuts and bolts
  • Sledgehammer head

You can start the process by building the platform where the power hammer sits. Then, it is all about woodworking. If you have some experience in woodworking, you’ll surely love this task.

Bicycle-Powered Hammer

Here is another method by that you can easily build a homemade power hammer. However, for this process, you’ll need a bicycle. First, you’ll have to remove the bicycle tires; you only need the rims for this process. Then, you can complete the base. Watch the full video for more details.

These are the different types of power hammer-build ideas. Choose one, make a plan and build a DIY power hammer.

Take a look at some of our related articles below.

Video References

Sek Austria

Светлана Вячеславовна

Advanced engineering technologies

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About Sam Orlovsky

AvatarCertifications: B.E.E.
Education: University Of Denver - Electric Engineering
Lives In: Denver Colorado

Electrical engineering is my passion, and I’ve been in the industry for over 20 years. This gives me a unique ability to give you expert home improvement and DIY recommendations. I’m not only an electrician, but I also like machinery and anything to do with carpentry. One of my career paths started as a general handyman, so I also have a lot of experience with home improvement I love to share.

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