How To Build A Wood Mallet

For this project I decided to use some fancy leftover coconut palm wood but any wood will do.

How to build a wood mallet. The wood acts as a shock absorber and takes most of the impact. Too late the change the picture. You can get by by using a regular claw hammer and a block of wood but for convenience a wooden mallet would be handier.

The Making of a Wood Jointers Mallet Making a wood mallet is a quick an easy woodworking project anyone can do with some basic woodworking tools. I think thats the best way to make a mallet since it can be done all in one session without waiting for glue to dry. Like the original the handle will be tapered and wedge into a tapered mortise in the head.

Glue the mallet head together. Now glue your 45 mm pieces on the outside of the handle but dont glue the handle itself. Make a Wooden Mallet -.

Take this clamped assembly to a drill press and drill two 18in holes on each center piece not the handle. Mill the wood to Size. The handle locks into a wedge-shaped mortise for a fit that tightens with use.

Of course that also means you need to layout and cut a tapered mortise but this is woodworking after all you love it and might need the practice. My hands flipped over a chunk of wood that fell as an offcut from the chopsaw a few weeks ago. Building a DIY mallet is a great woodworking project for beginners but that doesnt mean they cant be beautiful.

A basic wooden mallet is probably one of the easiest things to build and does not take a lot of experience or material. I begin by cutting the hammer head to 55 long 2 tall out of 15 thick stock. To drill the dowel holes first clamp the two middle pieces to the handle as they will be when assembled.