This project was created by Gunflint Designs. This article will walk you through making a stunning mallet using Ash and Black Walnut.
Materials and Tools Needed
- Ash wood
- Black Walnut wood
- Lead for added weight
- Wood glue
- Wood finish (optional)
- Chisel
- Mallet
- Band saw
- Drill
- Clamps
- Safety glasses
Step 1: Selecting Your Wood
Start by selecting your Ash and Black Walnut pieces. Ensure they are free of defects and suitable for a mallet’s structure. You want a piece of Ash for the handle and a solid piece of Black Walnut for the head of the mallet.
Step 2: Cutting the Wood
Using the band saw, cut the Ash to the desired length for your handle. You can customize the length based on your preference for grip. Next, cut the Black Walnut to form the mallet head.
Step 3: Shaping the Mallet Head
Shape the Black Walnut piece into a mallet head. You can decide on the dimensions, but it should be proportionate to the handle length. This is the part where you can get creative with the design!
Step 4: Drilling and Fitting
Drill a hole into the center of the mallet head where the handle will fit. Ensure the hole is snug enough to hold the handle securely. Test fit the handle into the hole to make any necessary adjustments.
Step 5: Adding Weight
To enhance the mallet’s performance, consider adding lead for extra weight. Melt the lead and pour it into the head of the mallet before securing the handle. This step will give your mallet a satisfying heft, making it more effective for striking.
Step 6: Assembly
Once you are satisfied with the fit, apply wood glue to the handle and insert it into the mallet head. Use clamps to hold everything in place while the glue dries.
Step 7: Finishing Touches
After the glue has dried, you can sand the mallet to smooth out any rough edges. If desired, apply a finish to protect the wood and enhance its appearance. This could be an oil finish or any other wood finish of your choice.
