A Shop-Built Mallet Made With Scrap Wood!

Get the step-by-step plans to build this Shop-Built Mallet here: www.woodsmithp...
A hefty solid-wood mallet is a great tool for assembling projects, or for gentle persuasion when you don't want to mar a surface. Designer, John Doyle, made one from some scrap wood he found in the shop and shows you just how it's done. You're sure to learn some great tips for shaping wood in this how-to video.
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[@drobb4207]

This is a great project! Yesterdays oven rack pull/push tool was also a great video. That rack tool is a perfect project for any parent teaching kids to use simple tools in the shop. Don

[@WoodsmithShowandmagazine]

Thanks, Don!

[@theguitarpicker]

any chance you have the link to that vid?

[@WoodsmithShowandmagazine]

@@theguitarpicker - I think that Don is referring to this video: kzbin.info/www/bejne/r6mQaHyvn8uaiLs

[@JusBidniss]

Great ideas on the router boxes and bridge, takes out all the guesswork, and lets you batch out a lot of identical ones. Also great idea on cutting a dado in the inner part of the head for the handle tenon. For those who cannot cut that dado easily (either no dado stack, or no flat-tooth blade to nibble it away), it occurs to me you could also just cut the handle tenon first, glue up those inner layers you dadoed that are the thickness of the tenon, then cut them in two. Then butt the cut ends against the handle tenon, do the brad nail maneuver on a full layer over them, flip it over and brad nail another layer on that side ('constructing' the mortise around the tenon). Then remove the handle before any glue squeeze-out sets up, and complete the remaining layers on both sides.

[@jimparsons6803]

Liked the approach of using what you already have to make a useful tool

[@markschneider1366]

I never thought of that tapered jig to help shape and contour the handle on the router table . I always used a rasp to round and shape . I'll have to give it a try ! Thanks for the tip. !

[@markpalmer3071]

That's a great project, I love the router boxes

[@williamellis8993]

The boxes for shaping the handle and the bridge for the router table are great ideas.

[@WoodsmithShowandmagazine]

Thanks!

[@henryworkswoodandmetal]

The router box and bridge are great jigs for this project.....nice video!!!

[@WoodsmithShowandmagazine]

Thanks!

[@afzulali7695]

Again absolutely brilliant well done guys thank you.

[@WoodsmithShowandmagazine]

Thanks :)

[@mountainviewturning5319]

Great looking mallet

[@aliharday3402]

Thank you for your excellent idea

[@WoodsmithShowandmagazine]

Thanks for watching! :)

[@bfobian9016]

Nice project! ... Kinda like the chicken or the egg- uses a mallet to build a mallet.. (plus a hammer). ; ) Still nice.. Thanks!!

[@WoodsmithShowandmagazine]

Yes! Finally somebody comment on the irony of me using a mallet to make a mallet! I could have tapped that head on with something else or the the workbench surface, but I thought it would be funny to grab the other mallet. I was really disappointed nobody had mentioned that yet. Thank you!

[@jimredding7828]

You have some really good ideas. I’m assuming you tapered one end of the mallet head to get into smaller spots?

[@WoodsmithShowandmagazine]

Yeah, it's based off an old cabinetmaker's mallet design, and I believe you are correct that the back side is used to get in tight spaces.

[@Alfetta158]

Fortunately, you already had a mallet to help you make another mallet. some of us beginners aren't so lucky. 😏

[@brucelee3388]

Make sure you put your name or maker's mark on it so it doesn't grow legs and wander off.

[@WoodsmithShowandmagazine]

I actually gave this one to my dad for Father's Day, so time to make another one :)

[@theguitarpicker]

I know I've seen this in a past issue of Woodsmith… any idea what issue number it was?

[@WoodsmithShowandmagazine]

This mallet was from ShopNotes Magazine issue# 95.

[@theguitarpicker]

@@WoodsmithShowandmagazine Thank you

[@terryeby947]

You would look 100% better if you would put on a shirt ,shower and shave below going in public.

[@WoodsmithShowandmagazine]

Thanks, Terry! Great Tip... I'll consider doing that next time I "below going in public." I could probably stand to lose 20-30 pounds too. :)

[@mattlewandowski73]

if you put on a shirt, shower, and shave, you are going to look a bit silly with a wet shirt :P