This project was built and designed by Sam Macy. It’s a simple but essential addition to any workshop—a solid wooden mallet built from cherry and maple.
Every woodworker can benefit from having a dedicated mallet in their tool collection. Whether for tapping joints or light chiseling, this project is a great introduction to combining hardwoods in a functional tool.
Watch the full video and subscribe to Sam’s channel:
Choosing the Materials
Sam selected maple for the handle and cherry for the mallet head. Cherry offers strength with a warm, classic appearance, while maple is known for its toughness and comfort in hand.
While preparing the wood, Sam came across a few small cracks in the cherry. Instead of discarding the piece, he chose to incorporate the flaws into the final design, giving the tool a bit of rustic character.
Preparing the Wood
The first step was to flatten and square the stock. After milling, the pieces were cut to size, ensuring they were ready for shaping and turning.
The handle was turned on the lathe to give it a comfortable grip. A one-inch diameter was maintained at the top to make joining the head and handle straightforward.
Shaping the Mallet Head
After cutting the corners off the mallet head on the bandsaw, Sam shaped the head using the lathe. The goal was to create a rounded, balanced form that would feel natural during use.
The final shape ended up being more rounded than originally planned, giving the mallet a playful look. With some light stain and finish, the result took on a rugged, shop-ready appearance.
Assembly and Epoxy Joinery
Instead of using angled cuts and joinery, Sam drilled a clean hole through the mallet head and set the handle in place with epoxy. This simplified the build and created a solid connection between parts.
Though epoxy can be tricky, a clean pour and a snug fit resulted in a strong bond. Any small gaps were filled and sanded smooth before finishing.
Lessons and Takeaways
The project had a few minor imperfections, including marks from the lathe and slight shifts during shaping. However, each of these added character and helped shape the overall learning experience.
If approached again, Sam noted he might use a router or alternate shaping tools to refine the edges. Still, the build turned out solid and functional, making it a useful tool for the shop.
Final Thoughts
This wooden mallet project is a great way to practice using hardwoods, shaping on the lathe, and experimenting with epoxy joinery. It’s a tool that will see regular use and serve as a reminder of the skills developed along the way.
For anyone looking to build a custom mallet with a personal touch, Sam’s approach offers a balance of simplicity and craftsmanship. The final result is practical, durable, and rewarding to make.
Want to See the Full Build?
Please support Sam by visiting his website here: https://sammacydesigns.com/