Nice post. Language interests me.
The word "maul" is derived from the Latin malleus, meaning a hammer. The affix "-et" or "-ette" is usually a diminutive. I always figured a "mallet" (maul-ette, as a "cigarette" is a "little cigar") was a "little hammer".
When I was a kid, my dad kept a maul made of hickory. It was probably 3-1/2 feet long, with a head 7" or 8" in diameter. We used it for driving wedges for splitting firewood. I called those crude, smaller creations of mine (post #28) "hand mauls" to distinguish them from the big mauls I remember seeing long ago. I guess a "mallet" would be somewhat smaller yet. Language evolves, and it appears to me that we generally now use the term "mallet" to mean a tool with a non-metallic head, or at least a head that is not iron or steel, to distinguish it from a hammer, with a steel or iron head. Just conjecture on my part.
That Saddler's Manual sounds like an nice reference. I think words are artifacts, just as surely as guns, knives and powder horns are artifacts. If we are interested in making and using the old-style guns and tools, I think we should take an interest in the words that were applied to them. It gives us a window into the past.
Best regards,
Notchy Bob