This wooden mallet project was created by Biscuit Tree Woodworks, and it’s perfect for beginners and seasoned woodworkers alike. Not only will you end up with a useful tool, but you’ll also gain the satisfaction of having made it yourself!
Materials Needed
- Piece of oak for the mallet head
- Scrap wood for the handle
- Wood glue
- Brad nails
- Watco Danish oil (for finishing)
Tools Required
- Jointer
- Bandsaw
- Planer
- Miter saw
- Router with a chamfer bit
- Clamps
- Sanding equipment
Step 1: Prepare the Mallet Head
Start by jointing two faces of your oak piece to ensure they are smooth and square. After that, use the bandsaw to resaw the oak into two boards, each about one inch thick. Finally, plane these boards down to ensure all faces are parallel.
Step 2: Cut the Mallet Head Pieces
Once your pieces are milled to the same thickness, set your miter saw to a 2.5-degree angle and cut one end of each board to create a wedge. Then, cut the pieces to the required lengths: two at 3.5 inches and two at 7 inches.
Step 3: Glue Up the Mallet Head
Arrange the pieces for the mallet head and apply glue to the edges. Use brad nails to hold them in place while the glue dries. Be sure to clean out any excess glue that may squeeze into the handle slot.
Step 4: Shape the Handle
Next, prepare the handle by trimming it to about 14 inches long. The width should be about 1.25 inches. Use the router with a chamfer bit to shape the handle, ensuring it’s comfortable to hold.
Step 5: Assemble the Mallet
Now it’s time to assemble your mallet. Fit the handle into the head, making sure it’s a snug fit. Use wedges to secure the handle in place, adding glue as necessary.
Step 6: Sand and Finish
After the glue has dried, sand the mallet to remove any rough edges. Apply a few coats of Watco Danish oil to protect the wood and enhance its appearance. Allow time for the oil to soak in between coats.
And there you have it! A beautiful, handcrafted wooden mallet that you can use in your workshop and pass down to future generations.