This project was built and designed by Jay Bates. It features two shop mallets—one for personal use and one as a gift—each designed with a clean friction-fit handle and thoughtful shaping for comfort and control.
Rather than relying on glue or wedges, Jay uses a tapered mortise-and-tenon connection that allows the handle to be removed or replaced as needed. It’s a simple yet smart approach that highlights both form and function.
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Why a Rectangular Handle Works Better
Jay prefers a rectangular profile for the mallet handle because it naturally fits the hand. The design allows the fingers to rest against the sides, offering a more secure and relaxed grip.
By tapering the handle from top to bottom, the mallet feels right no matter how it’s picked up. This orientation also makes it easier to avoid awkward hand positions, especially during long woodworking sessions.
Choosing and Prepping the Material
The first mallet is made entirely from a single piece of oak. Despite a few imperfections in the scrap wood, there’s enough usable stock to produce both the handle and head.
The head block is large and sturdy, with square long grain sides and end grain that needs some shaping. For the second mallet, Jay moves to laminated pieces of walnut to streamline the process and make multiple mallets at once.
Tapering the Mallet Head Safely
To shape the striking faces of the mallet, a slight taper is added to both ends. This improves performance and appearance while reducing the risk of splitting along the edge.
Jay uses a miter saw to make these angled cuts but takes extra safety precautions by creating a sacrificial support from scrap plywood. This stabilizes the piece and avoids the risk of rocking or binding during the cut.
Bandsawing and Shaping the Handle
A straight-grained piece of oak is selected for the handle, chosen for its strength and flexibility. Jay marks out the tapering profile and cuts it on the bandsaw, ensuring the shape narrows just enough to pass through the mallet head snugly.
The handle is further refined using a hand plane to get smooth surfaces and to make subtle adjustments for fit. The rectangular profile is retained, with softened corners to improve comfort without sacrificing control.
Making the Mortise
With the handle shaped, Jay turns to creating the mortise in the mallet head. He uses dividers to mark the width of the handle, transferring those measurements precisely to the head.
The majority of the waste is removed using a drill press. After that, sharp chisels are used to clean up the mortise walls, producing a snug and accurate opening for the handle.
Fine-Tuning the Fit
At first, the handle is slightly oversized and won’t pass through the mortise. Jay uses a hand plane to remove small amounts of material, testing the fit as he goes until it slides through with firm pressure.
Once the handle is fully seated, any excess is trimmed off flush. The edges of the mallet head are chamfered with a block plane or router to remove sharp corners and give the mallet a more finished appearance.
Creating Multiple Mallets Efficiently
The second mallet follows the same principles but uses laminated stock to speed up the process. This allows Jay to make five mallet blanks from a single section of walnut, each one slightly different in shape and feel.
By using a repeatable design and power tools for the lamination, the mallet build becomes ideal for batch production. Each mallet retains a handmade quality, but with enough efficiency to make gifting or selling them worthwhile.
Sanding and Applying Finish
All edges are chamfered and smoothed with 220-grit sandpaper, giving the mallets a clean and comfortable feel. Danish oil is applied to highlight the natural tones of the wood and provide light protection.
The final result is a pair of attractive, durable shop tools that are built to last. The friction-fit design also means they can be maintained and repaired easily, making them a long-term addition to any woodworker’s tool set.
A Fun and Functional Project
Jay’s mallets show how even a small woodworking project can be deeply satisfying. Whether crafted from a single block or made from laminated scrap, each mallet is a useful reminder of the creativity and care that goes into handmade tools.
This project is ideal for woodworkers looking to refine their joinery skills, practice safe shop techniques, or simply enjoy the process of making something that will get used daily.
Please support Jay by purchasing his plans here: Jay’s Custom Creations.