Wooden Mallet out of reclaimed scrap lumber

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Project by palaswood posted 292 days ago 1604 views 3 times favorited 12 comments Add to Favorites Watch

I messed around and made a wooden mallet the other day. My first attempt below, using doug fir for the mallet head and a rough turned handle out of SPF lumber reclaimed from an apartment complex property renovation

This project is my 2nd attempt, and think i’m getting the hang of it now.

So having cut in half a planed down 2×4 section, I glued it back on itself, so as to sort of “bookmatch” the endgrain pattern.

No pics of the glue up, but its pretty straightforward.

I planed it to shape best I could, then ROS sanded with 60 grit to get the endgrain down to a nice glue line and flat.

Then I drilled a hole down the center.

The hole on the first mallet was VERY off center coming out the bottom, and I got mad tear-out, so putting a block under would really help (which i neglected to do again!). I was really careful to watch the level bubble on the drill back this time, since no drill press :(

Worked well. I then turned the handle on the lathe out of a blank of really light, but strong straight-grained douglas fir from a reclaimed 2×4. Now they are sanded to 400 grit and ready to assemble.

I split the end of the handle with my dovetail saw, then widened it with the miter saw & drilled the bottom so it wont split

I didnt use glue, just wanted a wedge alone. I made the wedge from a strip of walnut cutoff from a cabinet shop near my workplace.

Didn’t quite fill the slot completely. I have a gap on one side.

So I improvised by adding a mini wedge piece and it doesn’t look too shabby after some clean up with the chisel, knife and sandpaper.

Sanded smooth to 600

The finished piece after applying Watco Danish oil

This was so much fun, and I completed it in about 3 hours, not counting the previously glued up head piece.
I believe its time to graduate to some hardwoods…

-- Joseph, Lake Forest, CA,

12 comments so far

View Surfside's profile


3072 posts in 797 days

#1 posted 292 days ago

Absolutely delightful. Clean design and obviously gorgeous.

-- "someone has to be wounded for others to be saved, someone has to sacrifice for others to feel happiness, someone has to die so others could live"

View chrisstef's profile


10611 posts in 1630 days

#2 posted 292 days ago

That’s a serious thumper there bro. Smash something with it!

-- "there aren’t many hand tools as awe-inspiring as the #8 jointer. I mean, it just reeks of cast iron heft and hubris" - Smitty

View snowgoer's profile


78 posts in 1291 days

#3 posted 292 days ago

Pretty piece of wood. Well done! Now tell me you won’t strike another object with that thing.

View whitebeast88's profile


3465 posts in 814 days

#4 posted 292 days ago

great mallet,excellent build.

-- Marty.Athens,AL

View doubleDD's profile (online now)


2363 posts in 667 days

#5 posted 292 days ago

I really enjoy looking at this mallet. Different than others posted here, Nice work.

-- --Dave, Downers Grove, Il. When you run out of ideas, start building your dreams

View palaswood's profile


689 posts in 375 days

#6 posted 292 days ago

Thanks everyone. @DoubleDD – Yeah, i think so too. Its built for function, yet I wanted a smooth design that looks burly, yet classy and… chunky, to borrow a term my girlfriend uses for jewelry. I’m gonna build some more. They are light, but REALLY solid. Fun and quick to build.

I’ve got some old growth stuff I’m gonna use for the next one I believe. Should be much more dense. Maybe a hardwood edition is forthcoming

-- Joseph, Lake Forest, CA,

View ColonelTravis's profile


571 posts in 518 days

#7 posted 292 days ago

that thing is HUGE!

View WayneC's profile


12260 posts in 2721 days

#8 posted 292 days ago

It is a brute. I bet it gets lot of use.

-- We must guard our enthusiasm as we would our life - James Krenov

View plang's profile


105 posts in 1978 days

#9 posted 291 days ago

Built one similar, but not as nice as yours. Only problem is my grandson confiscated it and uses it as his Thor hammer. As long as he only pretends to throw it and it makes him happy, I’m OK with it. I can always make another one. Keep up the beautiful work.

View palaswood's profile


689 posts in 375 days

#10 posted 291 days ago

Its the camera angle, its not THAT big. It sure is beefy though. This is more or less a true angle. I dont have big hands, btw.

-- Joseph, Lake Forest, CA,

View JoeinGa's profile


3157 posts in 631 days

#11 posted 291 days ago

THAT’s not a mallet! THAT’s the Hammer of THOR!

NICE! :-)

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View arthurbvb's profile


18 posts in 301 days

#12 posted 291 days ago

Love the mallet, very nice

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