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Project by PurpLev posted 1436 days ago 2965 views 17 times favorited 27 comments Add to Favorites Watch

Pallet to Mallet,
a Mallet from a Pallet.

I needed one for a very long time as I always seemed to be using the closest available heavy block of wood for chisel work. I ended making this one from a single Oak pallet slat that had some nice figure to it.

head is 3”x5”x~2.5” – laminated 4 layers
handle is 1 1/4x~1 1/4”x as long as I could have it (for balance). It’s ~16” long (through the 3” head)-laminated 2 layers

The handle is not glued to the head, but is wedged in. the inner parts of the head are cut at 2° on each side, and a wedge with edges at 4° once pounded in (with glue) presses the handle tight into the head, while also keeps it from moving with the now wedged/slopped handle top – its basically locked in.

The head faces are both cut at 1° slope to follow the direction of the blow better.

finished with 2 coats of BLO.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

27 comments so far

View jack1's profile


1907 posts in 2622 days

#1 posted 1436 days ago

Looks like a good mallet. It does have a good figure.

-- jack -- ...measure once, curse twice!

View Lenny's profile


1229 posts in 2122 days

#2 posted 1436 days ago

That’s a great save Sharon. Pallet to mallet indeed. Instead of being in a landfill, this oak will be helping you make fine projects.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View littlecope's profile


2879 posts in 2097 days

#3 posted 1436 days ago

Good Looking Mallet, Sharon… Being Oak, that must have some nice heft to it…

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Gary Fixler's profile

Gary Fixler

1000 posts in 1977 days

#4 posted 1436 days ago

Very nice! I might like to follow along with my own mallet one of these days. I have a lot of pallet wood here.

-- Gary, Los Angeles, video game animator