Completed my first wood mallet - Router Forums
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post #1 of 21 (permalink) Old 10-18-2019, 01:20 AM Thread Starter
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Default Completed my first wood mallet

I just wanted to show my first mallet that I have completed. The handle is made from a piece of pine I had laying around that I shaped with a plane, router and sander.
The head is made from some wood I kept from old posts when I had the boundary fence renewed about two or three years ago. I removed all the nails and then ran it through my small planer/thicknesser and I was happy with the outcome and how good the wood was.

The dark wood on the outside of the mallet head is red gum from an old fence post. I'm not sure what the lighter wood is. All I know is it was an old fence post as well.

I was playing with the router profiles a bit when I did the handle and used a large round-over bit. I cut some shallow plugs of red gum with a hole punch and drill three recesses in each side of the handle. I glued in the plugs and sanded them flush with the handle sides.

The screw in the center is two 6mm screws with a steel tube mounted in the handle and threaded. Almost like a Chicago screw.
The handle is fitted into the head with wood glue, silver screws fitted and wedges installed.

All was finish sanded, oiled and waxed.

I did split the handle near the head when I drove the wedge in and had to drill and fill the crack

I'm happy with the result and have wanted to make a mallet for a while. It will probably become a "shelf queen" for the moment. It is quite light in the hand, surprisingly.

Thanks to those on the net that gave me the inspiration to build this.

You can see some of my other projects in my album: https://www.routerforums.com/members...om-albums.html
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There's nothing like the smell of raw wood in the morning!!

Last edited by Old_Tom; 10-18-2019 at 01:23 AM. Reason: Added link to my album
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post #2 of 21 (permalink) Old 10-18-2019, 01:24 AM
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I'm so happy w/ your results I'd be ecstatic to take that off of your hands...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

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post #3 of 21 (permalink) Old 10-18-2019, 05:29 PM
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Nice looking mallet. Interesting handle design, was that your design or was that something you saw when you were researching for the project?
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post #4 of 21 (permalink) Old 10-18-2019, 07:29 PM
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Really nice work, loving the little details

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post #5 of 21 (permalink) Old 10-18-2019, 08:07 PM Thread Starter
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Quote:
Originally Posted by Stick486 View Post
I'm so happy w/ your results I'd be ecstatic to take that off of your hands...
Thanks Stick but this one stays with me!

Quote:
Originally Posted by MEBCWD View Post
Nice looking mallet. Interesting handle design, was that your design or was that something you saw when you were researching for the project?
Thanks Mike. The handle design was originally unintentional. The original handle girth felt "fat" in my hand so I was looking for ways to minimise it, but only a fairly small amount. So I though of this design, probably got the idea from seeing some fantasy hammers online. I cut a large dado using the saw table and rounded off. It felt good in the hand. I thought it was going to feel funny using the hammer the other way around, but it feels okay.

Quote:
Originally Posted by RainMan 2.0 View Post
Really nice work, loving the little details
Thanks Rick. Yeah the handle looked bare and it needed some detail. Simple but effective.

Again thanks all. I did enjoy doing this one.
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There's nothing like the smell of raw wood in the morning!!
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post #6 of 21 (permalink) Old 10-18-2019, 08:14 PM
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Very Nice...Unique...

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post #7 of 21 (permalink) Old 10-18-2019, 08:34 PM
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That is a really nice piece! Never seen a mallet anyting like that, and I also like the shape of the handle.

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post #8 of 21 (permalink) Old 10-18-2019, 10:46 PM
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I like it - good job, Tom!

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post #9 of 21 (permalink) Old 10-19-2019, 10:22 AM
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Nick used the very word that I intended using, UNIQUE and beautifully made.

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post #10 of 21 (permalink) Old 10-19-2019, 12:39 PM
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Red gum is not something we'd find in a fence post around here. It adds a nice contrast to the mallet, Tom. Is that a soft or hard wood?

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