This wooden mallet project was created by Jesse from Penalty Box Woodshop. Follow this guide to make your very own mallet that’s both functional and satisfying to use.
Step 1: Prepare the Wood
Start by selecting the wood for your mallet. For the mallet head, use Duke for the middle section and air-dried walnut for the outer sections. Cut the boards down to manageable lengths and make them 2.5 inches wide using the table saw.
Step 2: Cut the Pieces to Length
Next, cut all three pieces to 4.5 inches long using the miter saw.
Step 3: Create the Handle
For the handle, choose hard maple. Cut it to 11.5 inches long and 1.5 inches wide. The thickness of the handle should match the thickness of the middle section of the mallet head.
Step 4: Shape the Handle
Raise the table saw blade to 2.75 inches high and use a universal tenon jig to cut shoulders on the handle. This will create a stopping point when attaching it to the mallet head.
Step 5: Create the Slot for the Wedge
After marking the center point of the handle, make a single cut for the slot that will accept the wedge.
Step 6: Assemble the Mallet Head
Align the slot of the handle with the center mark on one of the outside pieces of the mallet head. Apply glue and secure the middle section in place using brad nails until it can be clamped.
Step 7: Finalize the Mallet Head Shape
Clamp the pieces together and wipe off any excess glue. Use a drinking straw to clean the hard-to-reach areas. Set your miter saw at a 5-degree angle and cut the sides of the mallet head flush.
Step 8: Sand and Chamfer the Edges
Using a belt sander, sand all sides until even. Then, use the router table to put a small chamfer on all sides of the mallet head.
Step 9: Create the Wedge
Cut a wedge from a scrap piece of wood at a 3-degree angle. Apply glue and tap the mallet head into place until flush with the shoulder.
Step 10: Final Assembly and Finishing Touches
Align the blade with the top of the mallet and cut the handle on the wedge off flush. Finally, apply three coats of finish to protect your mallet.
