Making a mallet

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Blog entry by nobuckle posted 03-13-2011 03:02 AM 6384 reads 1 time favorited 7 comments Add to Favorites Watch

I finally got around to making a mallet. I started by selecting a piece of 6/4 Poplar, which yielded the material needed for the head and the handle. I then spent some time coming up with a design that would be to my liking. Once the design was settled on I glued up the material for the head and turned the handle on the lathe. After the glue dried I used my power mitre saw to cut the head to its rough shape. I then set up the drill press, with a 1” forstner bit, to drill the 3” deep hole needed for the tennon on the handle. Next it was over to the bandsaw to finish cutting the head to shape. After some sanding at the sanding station I used my trim router, outfitted with a 1/4” round over bit, to ease the edges. I then glued the head and the handle together. I created a short video that shows my progress. You can view the video via the following link to Youtube:


Here are some photos as well.

Material that will be the head and the handle

The final shape of the handle

Waiting for the glue to dry

Still waiting for the glue to dry

It’s starting to take shape

I have yet to apply any kind of finish. I plan to make a final video for this project that shows the finish being applied. I’ll post the Youtube link as soon as I have it finished.

Thanks for looking.

-- Doug - Make an effort to live by the slogan "We try harder"

7 comments so far

View Roger's profile


20929 posts in 2854 days

#1 posted 03-13-2011 03:15 AM

Oh you can make some good adjustments with that. very nice
I like how you’ve got your router, complete w/miter slot, to the left of your TS blade.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

View dbol's profile


136 posts in 3048 days

#2 posted 03-13-2011 03:39 AM

Poplar? Isn’t that pretty soft for a mallet? It looks real nice tho.

View WoodworkingGeek's profile


181 posts in 2742 days

#3 posted 03-13-2011 05:26 PM

Great job on the mallet!! poplar is a great choice because it will not damage tools like wooden handed chisels.

View Dandog's profile


250 posts in 2824 days

#4 posted 03-14-2011 02:59 AM

I like the way you go about things your layout. It all makes sense now that I know your a machinist. That’s a cool adapter I think I want to make one. I also think it’s a good choice of wood for Mallet head.good job on the video.

-- life an woodworking is one big experiment

View Rustic's profile


3253 posts in 3646 days

#5 posted 03-14-2011 06:58 PM

It is pretty soft. But I guess still usable. Plus it gives him a good start to build one out of maple

--, Rick Kruse, Grand Rapids, MI

View nobuckle's profile


1120 posts in 2811 days

#6 posted 03-14-2011 11:03 PM

I was under the impression that Poplar, being a closed grain wood, is considered to be a hardwood. Ideally I would love to make one out of Maple. Thus far I have the material needed to make the handle for a Maple mallet, but I lack that which is needed to make the head. This is the style of mallet I plan to make when I have enough material to make it:

When that time comes I will post a new video along with some pics. I’m thankful for the experience I’ve gained from making the first one.

-- Doug - Make an effort to live by the slogan "We try harder"

View WoodNuts's profile


74 posts in 2998 days

#7 posted 03-23-2011 06:38 PM

We all start somewhere, and I…have not started on one of these yet.

Hmmm, I’ll have to find a fix fer dat.

So anyway, it gives me something to think about. I have seen some mallets in a stroe, and let me tell ya, the price tag suggests they are verrry proud of their product.

I’ve got a hunk of hickory, I wonder if that would fit the bill.

What type of finish you all gonna use?

-- ...there's a fix fer dat...

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