2 Ways to Make a Mallet

This project, created by Jay Bates, showcases two effective methods for crafting a mallet.

Whether you need a new tool for your shop or a thoughtful gift, this guide will walk you through the entire process of making a mallet from scratch.

Step 1: Understanding the Design

The first step in creating your mallet is to decide on the design. This project features a two-piece mallet where the handle and the head are not glued together. Instead, they fit together using friction. This design allows for easy replacement of the mallet head if it gets damaged, preserving the handle that you’ve grown accustomed to.

Another important aspect of the design is the rectangular profile of the handle, which is tapered from top to bottom. This shape is more comfortable for many users, as it fits naturally in the hand and ensures you can easily tell which way is up when gripping it.

Step 2: Gathering Materials

For the first mallet, you will need a piece of oak for both the mallet head and the handle. If you have scrap wood lying around, this is a perfect opportunity to use it. The mallet head should be roughly three inches square, while the handle can be around 14 inches long with a taper of half an inch from top to bottom.

Ensure that the wood you choose is free from major defects, as these could affect the strength and durability of your mallet.

Scrap oak for mallet

Step 3: Cutting the Mallet Head

To create the mallet head, start by marking the centerline on all four faces of your block of oak. Next, use a miter saw to put a slight taper on the faces that will be the business end of the mallet. This taper will help in striking surfaces more effectively.

To ensure safety while using the miter saw, create a sacrificial table and fence from scrap plywood. This will provide additional support and stability while cutting.

Using a miter saw for taper

Step 4: Preparing the Handle

With the mallet head prepared, it’s time to focus on the handle. Cut a straight piece of oak to your desired length, making sure to account for the taper. The handle should have enough thickness to fit snugly through the mortise that you will create in the mallet head.

Once cut, use a hand plane to refine the shape of the handle for a better fit. The handle should pass through the head of the mallet smoothly, providing an ergonomic grip.

Preparing the handle

Step 5: Creating the Mortise

Next, you will need to create the mortise in the mallet head to fit the handle. Start by marking the dimensions of the mortise using dividers or a compass to ensure accuracy. Drill out the majority of the waste using a drill press, working from both sides to meet in the middle.

This technique will help maintain the integrity of the mallet head while also ensuring a clean mortise for the handle.

Drilling the mortise

Step 6: Fitting the Handle

After creating the mortise, check the fit of the handle. It should fit snugly but not so tight that you cannot adjust it. If it’s too tight, use a hand plane to shave down the sides of the handle until it fits comfortably.

Once the handle fits well, drive it fully into the mortise until it reaches your predetermined line. If you have excess length, you can trim it down later.

Fitting the handle

Step 7: Finishing Touches

With the mallet assembled, it’s time for the final touches. Use a chamfer bit or sandpaper to round the edges slightly. This will not only improve the aesthetics but also make the mallet more comfortable to use.

For a finished look, apply a coat of Danish oil or any finish of your choice. This will protect the wood and enhance its natural beauty.

Finishing touches on the mallet

Step 8: Creating Additional Mallets

The second method of making a mallet involves using power tools to create multiple mallets from a single piece of wood. In this case, a 15-inch section of four-quarter walnut can yield enough material for five mallets. This method allows for a quicker process and more creative designs.

Each mallet can be customized in size and shape, giving you the freedom to experiment with different styles while still maintaining the fundamental construction techniques.

Multiple mallets made from walnut

Conclusion

Crafting your own mallet not only enhances your woodworking skills but also provides you with practical tools that can be used for various projects. Whether you choose to make a single mallet or several, the process is straightforward and rewarding.

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