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Making a Wood Mallet

30K views 38 replies 21 participants last post by  harrysin 
#1 · (Edited by Moderator)


This is a simple project that requires some router work and gives you a useful tool as an end product.

It requires 5 pieces to build.

The diam of the head is 4 3/4" long,3 1/2" high, and 2 1/4" wide. this requires 4 pieces

The handle it 13" long X 3/4" thick,and tapes from top to bottom 1 1/2"-1 5/16".

I made a jig so that when the head is built the hole will fit the taper of the handle.

While the head was glued up and waiting for the glue to dry, I made the template to route the contour of the handle.

When the head was ready I cut the face at a 5 degree angle and installed the handle from the top down and drove some wedges into the top of the handle. Then cut off the extra wedges flush to the top of the head and sand the handle flush.

I finished the mallet with a coat of sanding sealer, a coat of shellac, and 2 coats of water based acrylic.

Herb
 

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#4 ·
excellent Herb...
and the handle idea is great...
 
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#5 ·
Great result....

Also like the detail on the handle...
 
#6 ·
Like the hammer ... I made one similar and actually named it Thor. (but I see you made enough for the whole Norse army or all the elves at the north pole with spares, coming up with enough names is going to be problematic). I like your dimensions better - think mine is a little too big. I tapered the handle to fit a matching taper in the hammer and skipped the wedges. Glued some leather to one face. I have a fix the "too nice to use" problem - skip the furniture grade finish :). Is it too late to join that club?
 
#7 ·
That's very nice Herb, but mine's BIGGER :wink:
 

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#20 · (Edited)
Paul,
I did cut the wedges and wedge slots on the band saw.

WARNING: I SHOULD MENTION HERE THAT BEGINNERS SHOULD NOT TRY TO ROUND THE END OF THE HANDLE TO SHAPE THE CURVE ON THE ROUTER. GO TO THE DISK OR BELT SANDER FOR THAT. GOING AROUND THE END TO RADIUS THE EDGE IS OK BUT UNLESS YOU ARE VERY EXPERIENCED, ROUTING AROUND END GRAIN IS DANGEROUS.:no::no::no:

Thanks for all the compliments, glad you enjoyed this thread.

Herb
 
#22 ·
Just cruisin' through and the post caught my eye. Nice work. Mallets are fun.

Here's one I did a while back.

 
#23 ·
Just cruisin' through and the post caught my eye. Nice work. Mallets are fun.

Here's one I did a while back.
do not use that mallet...
that would be a sacrilege...
 
#34 ·
This is a simple project that requires some router work and gives you a useful tool as an end product.

Herb
found a plan(s) for your next round of mallets...

.
 

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#36 ·
That really is a beautiful mallet. I'm too lazy to go to that trouble so this pdf shows how I made a one piece one which I have used quite a lot.
Your photo-shoot is perfect, more members should consider doing the same.
 

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