Mallet Faces

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Project by TerryDowning posted 157 days ago 722 views 0 times favorited 5 comments Add to Favorites Watch

While waiting for finish coats to dry on the Treasure Box and Cherry Box finished up this weekend, I replaced the faces on my plastic tipped mallet. While researching replacement faces, it was suggested that I make my own. These were turned on my lathe and were surprisingly simple to do.

I had some 2 ” Maple left over from a bowl I turned it round between centers marked out as many faces as I could with a parting tool. Drilled on end with a 1/4 ” drill so a 5/16×18 bolt could be screwed into place. Bolt was cut to length and held in my drill chuck for final turning to diameter and the little step that goes inside the head.

I managed to get 5 faces turned from Maple and one additional face from a scrap of delrin I had laying around. Time will tell how these turned out.

-- - Terry

5 comments so far

View Rick M.'s profile

Rick M.

3883 posts in 1013 days

#1 posted 157 days ago

Cool looking mallet. So do the faces just screw in?

-- |Statistics show that 100% of people bitten by a snake were close to it.|

View TechTeacher04's profile


166 posts in 164 days

#2 posted 157 days ago

You might want to make one out of a softer material. The benefit of the rubber mallet is that you will not mar the surface of your board. Maple heads will almost assuredly be harder than the work pieces you are using.

View TerryDowning's profile


1004 posts in 750 days

#3 posted 157 days ago

I have some pine scrap. Now that I know how easy these are to make, I can pretty much use any material available. The maple is actually pretty soft as I recall.

-- - Terry

View CFrye's profile (online now)


2843 posts in 473 days

#4 posted 157 days ago

Big improvement Terry! Handle next?

-- God bless, Candy

View TerryDowning's profile


1004 posts in 750 days

#5 posted 157 days ago

Thanks Candy.

No plans for replacing the handle until it’s far worse. It’s still doing the job, so I’m leaving it for now. The faces were pretty much done though. After 40+ years (at least. I’ve used this hammer my entire life and don’t ever remember it being different until now.) it was time.

-- - Terry

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