2 Hour Assembly Mallet

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Project by KnotCurser posted 12-19-2013 02:01 PM 1996 views 8 times favorited 12 comments Add to Favorites Watch

So, I have this 2 pound rubber headed mallet that is a perfect heft for cabinet assembly, but it’s a black rubber and it leaves really nasty scuff marks!

It was time to make my own!

While it’s not Thor’s Hammer, it is perfect for what I intend to use it for.

I used scraps from three previous projects as well as an old lining from a leather-lined breifcase which means NO COST!

The head is White Oak and Walnut and the handle is straight grained hickory.

I rubbed in a couple of coats of danish oil just to give it a nice finish and condition the leather a bit.

It weighs just over 1 1/2 pounds. I applied leather pads to the both heads to avoid denting my furniture.

The head is around 6×3x2 inches and the handle around 11 inches long.

From start to finish, to include waiting for the glue to dry took me two hours – thus the name.

I may make another one of these and put lead shot into the head for some more weight, but this one fits the bill nicely for aligning and coaxing mortise and tenon joints together.

I think that rubber mallet may be tossed into the back of a drawer somewhere and forgot about. ;-)



-- Robert Rhoades WoodWorks / Email: /

12 comments so far

View SPalm's profile


5325 posts in 4057 days

#1 posted 12-19-2013 02:10 PM

Nice, I use mine all the time.

Really consider the lead inside hogged out holes. I used fishing weights. Not that it adds weight, but if they are slightly loose inside, they will act as a counter weight and cause a dead bounce. It really works.

Smart idea about the briefcase leather. I use leather on one side, and just wood on the other. Both have their advantages.

Good job,

-- -- I'm no rocket surgeon

View helluvawreck's profile


32087 posts in 3042 days

#2 posted 12-19-2013 02:16 PM

Bob, this is a nice addition to your shop. Good work.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Sanding2day's profile


1014 posts in 2022 days

#3 posted 12-19-2013 02:50 PM

Very nice mallet… Not sure it is helpful at this point but if you wish to continue utilizing your rubber mallet and avoid the the black marks… This months Shop Notes had the tip of wrapping the head in an old sock, which I thought wasn’t a bad plan… Thanks for sharing…

-- Dan

View stefang's profile


16064 posts in 3509 days

#4 posted 12-19-2013 03:09 PM

Nice mallet Bob.

-- Mike, an American living in Norway.

View scrollingmom's profile


1188 posts in 2639 days

#5 posted 12-19-2013 07:15 PM

Very nice and bonus didn’t cost anything. Thats the way to go.

-- Kelly, Allen,KS

View dpow's profile


503 posts in 3019 days

#6 posted 12-19-2013 08:20 PM

Nice looking project. I especially like the handle design. Thanks for sharing.

-- Doug

View Woodfix's profile


343 posts in 3475 days

#7 posted 12-20-2013 12:02 AM

Very nice

-- I would rather have the most memories, than the most money.

View hoss12992's profile


4073 posts in 2068 days

#8 posted 12-20-2013 03:18 AM

Great job. I really like the handle on this one.

-- The Old Rednek Workshop

View laketrout36's profile


200 posts in 2202 days

#9 posted 12-20-2013 11:53 AM

Functional, looks good, price is great. You’ve got a keeper.

View KnotCurser's profile


2026 posts in 3244 days

#10 posted 12-20-2013 12:19 PM

Thanks for all the comments!

hoss, I traced a handle from an old hammer of my father’s that felt perfect in my hand and went from there until it was really comfy!


-- Robert Rhoades WoodWorks / Email: /

View 489tad's profile


3447 posts in 3187 days

#11 posted 12-20-2013 01:46 PM

Looks nice.

-- Dan, Naperville IL, I.G.N.

View Roger's profile


20949 posts in 2979 days

#12 posted 12-22-2013 02:45 AM

Very cost effective. Nice mallet

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

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