This project was built and designed by Connor from Shopfix. It’s a detailed breakdown of how to build a durable woodworking mallet using unique joinery methods and flexible design options.
Connor walks through everything from material selection to shaping and finishing, making this a great guide whether you’re making your first mallet or looking to improve on an old design.
Watch the full video and subscribe to Connor’s channel:
A Different Take on the Traditional Mallet
Unlike the common rectangular-handled mallet, this design uses a round handle for increased comfort and control. The handle is fitted through a drilled hole in the mallet head, eliminating the need for traditional chiseling.
What makes this project stand out is the side-wedged handle design. Instead of wedging from the top, the handle is secured horizontally with a dowel pin, creating a strong and serviceable connection without the need for glue.
Choosing the Right Wood for Performance
Selecting the right wood plays a big role in the mallet’s strength and feel. Hardwoods are the best option, and Connor discusses species like osage orange, known for its density and durability.
He also explores two common approaches for making the mallet head: laminating multiple boards or using a single solid block. Laminated designs can offer eye-catching contrast, while solid blocks tend to be stronger overall.
Preparing and Laminating the Mallet Head
If laminating, it’s important to square each board before glue-up. This ensures that the resulting block is solid and uniform, with no internal gaps that could weaken the structure.
Once the boards are glued and clamped, Connor mills the entire block to final size. This process creates a clean surface and prepares the head for accurate shaping and drilling.
Drilling the Handle Hole
The round handle design means the mallet head needs a centered hole. Connor drills this with a drill press to keep it precise, but a hand drill can be used with care and proper marking.
The handle itself can be either a turned dowel or a naturally rounded branch. The goal is a tight fit that holds under pressure, so matching the hole and handle diameter is key.
Enhancing the Shape and Function
To improve the look and balance, Connor adds a slight curve to the top of the mallet. This can be done freehand or with a printable template. After rough-cutting the shape, he sands it to a smooth finish.
Leaving a little extra material during the cutting stage allows for fine-tuning during sanding. This ensures symmetry and gives the final product a more polished feel.
Securing the Handle Without Glue
One of the most clever aspects of this project is the method for securing the handle. Instead of using adhesive or a top wedge, Connor inserts a dowel pin from the side of the mallet head.
This dowel crosses through the handle, locking it in place while still allowing the mallet to be serviced later. If the handle ever becomes damaged or loose, it can be replaced without rebuilding the entire mallet.
Sanding and Finishing
Once the mallet is assembled, it’s sanded to remove rough edges and tool marks. The goal is a smooth, comfortable grip and a head that won’t splinter or wear prematurely.
Several oil options can be used to protect the wood. Connor highlights Danish oil, tung oil, and boiled linseed oil—each offering different levels of sheen and durability while helping to bring out the grain in the wood.
Practical and Personalized
What makes this project great is its flexibility. You can use almost any hardwood species you have on hand, and the round handle with side dowel joinery makes it a forgiving yet reliable build.
Connor’s method also means your mallet won’t need glue or wedges to stay together, and future maintenance is easy. The design encourages a mix of utility and personal flair—exactly what shop-made tools are all about.
A Smart Addition to Any Woodshop
This mallet isn’t just a tool—it’s a great skill-building project. You’ll practice measuring, drilling, laminating, shaping, and joinery, all in one compact build.
Whether you’re flattening joints, adjusting pieces with a chisel, or simply enjoying a shop-made tool, this mallet will quickly become one of your most-used items.
Please support Connor by visiting his website: https://www.shopfix.services/.