How to Design a Wooden Mallet - Mallet Building Tips and Tricks

Learn how to design a woodworking mallet. These DIY wooden mallets are perfect for use around the shop for woodworking projects. This video will teach you how to build a mallet and more specifically my custom mallet design. I will cover all of the main features of this custom woodworking mallet. I will also detail all of the design features that you should consider when creating your own wooden mallet. There are several different ways to build a mallet and different designs for different purposes. For this mallet, I based many of the features on the joiners mallet which features beveled ends, and a curved top. Ultimately, this video will give you a great overview of the different ways to build a mallet, and what things you should consider when designing a mallet of your own.
#woodworking #mallet #mallets
Directions for creating my mallet design:
Head of Mallet
1. Made from one species of wood (better) or several boards laminated together.
2. The dimensions of the mallet head are 2.75" in height, 3" wide, and 6" in Length.
3. 7-degree bevel on both ends of the mallet head.
4. Small Chamfer on top and bottom sides of the mallet head (not on the end grain).
5. .5" diameter hole drilled 2" into one side of the mallet head after the handle has been properly placed.
6. 2.5" dowel, .5" in diameter is placed within the hole after a kerf is cut 1" down from the top of the dowel. After the dowel is placed 2" into the middle of the mallet head with wood glue then the excess of the dowel is trimmed flush
Handle
1. Made from a 1" diameter hardwood tree branch or 1" diameter oak dowel.
2. Handle extends 10.5" from the base of the mallet head.
3. Small chamfers on both ends of the handle.
4. Handle is placed into the head of the mallet without glue.
5. Handle is set within the mallet head until the handle extends 3/8ths above the top of the mallet head.
How to choose the right wood for your mallet
Download Lumber Hardness Rating Infographic here: drive.google.com/file/d/1ATKo...
How to create a joiners mallet curve
Download the template here: drive.google.com/file/d/1iQQY...
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0:00 Introduction
0:09 Custom Mallet Design Features
1:36 Selecting Wood For A Mallet
3:40 Laminating Boards Together for a Mallet Head
5:49 Creating a Joiners Mallet Curved Top
6:58 Inserting Handle Within Mallet Head
7:19 Securing Mallet Head to the Handle

[@_Shopfix]

Directions for creating my mallet design: Head of Mallet 1. Made from one species of wood (better) or several boards laminated together. 2. The dimensions of the mallet head are 2.75" in height, 3" wide, and 6" in Length. 3. 7-degree bevel on both ends of the mallet head. 4. Small Chamfer on top and bottom sides of the mallet head (not on the end grain). 5. .5" diameter hole drilled 2" into one side of the mallet head after the handle has been properly placed. 6. 2.5" dowel, .5" in diameter is placed within the hole after a kerf is cut 1" down from the top of the dowel. After the dowel is placed 2" into the middle of the mallet head with wood glue then the excess of the dowel is trimmed flush Handle 1. Made from a 1" diameter hardwood tree branch or 1" diameter oak dowel. 2. Handle extends 10.5" from the base of the mallet head. 3. Small chamfers on both ends of the handle. 4. Handle is placed into the head of the mallet without glue. 5. Handle is set within the mallet head until the handle extends 3/8ths above the top of the mallet head. How to choose the right wood for your mallet Download Lumber Hardness Rating Infographic here: drive.google.com/file/d/1ATKoVsB4o-DdWtDo7r6g1-WDqYEWh0bn/view?usp=sharing How to create a joiners mallet curve Download the template here: drive.google.com/file/d/1iQQYBZt1rKo_wQgbLsUtOeXxNUjDyDwR/view?usp=sharing

[@wmsymonds810]

I'm halfway through using round oak head and black walnut handle. My idea was to make it as rustic-looking as possible got some good ideas from you today thank you very much for the video❤

[@daviddent1384]

Excellent little video on making wood mallets. Thank you!

[@_Shopfix]

Hey, thanks for the feedback, glad you enjoyed it 👍

[@kodabug9]

Great video. I’m starting one today

[@_Shopfix]

Hope it turns out awesome!!

[@jsking1294]

This is wonderful. Thank you!

[@_Shopfix]

You're very welcome! I’m glad you enjoyed it

[@bruinsfan452]

Any reason to not just have the 1/2" dowel just go all the way through?

[@_Shopfix]

It’d be really hard to insert the dowel all that way with glue, the chances of it getting stuck are higher, if that makes sense.

[@rewind9536]

I use my mallet to hammer anything. With these designer mallets I would never dare to hammer anything.

[@_Shopfix]

Luckily they aren’t too hard to make so even if you wack anything with it, it probably wouldn’t be too hard to replace the mallet. However, I feel the same way like ‘what a nice mallet now let me smash it into stuff’ haha

[@EmmaGoodwinGeek]

I cringed when you were using the band saw.

[@Johnnyjjohnboy]

Came here to say roughly the same... never push your hands/fingers towards the blade, tablesaws aren't the only way to lose a finger.