How to Make a Wood Mallet

June 21, 2016


This week I’m making a wood mallet with some of the leftover wood from the pedalboard project I made a few weeks back. I used 3/4″ maple scraps and I had just enough to create the mallet. I used the template I created to cut out the handle and cut out 2-6.25″x3.5″ pieces and 2 more 2.5″x3.5″ pieces on my table saw. Once I had everything cut out, I thoroughly sanded the mallet until it was very smooth to the touch. I took the handle of the mallet and ran a 1/4″ round-over on both sides. I didn’t round-over the portion of the handle that will be glued into the mallet though. After I had everything ready, I went ahead and glued all of the pieces together. Once the glue was dried, I re-sanded everything and finished the entire project with some Danish oil. I really like how this project came out and it was a lot easier than I thought it would be. If you would like to make your own, I have a free template available for download.


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