How to Make a Wooden Mallet from Scrapwood

*Forgot to mention I used Tung Oil for the finish*
Looking for a fun and functional woodworking project? Learn how to make a strong mallet out of recycled pallet wood! This easy-to-follow video will guide you through the entire process, from finding the perfect pallet wood to the finishing touches. Perfect for beginners and experienced woodworkers alike, this mallet is a great addition to any toolbox.
Bonus: Pallet wood is free and readily available, making this project kind on your wallet and the environment!
In this video, you'll learn:
How to select the right pallet wood for your mallet
Essential woodworking cuts and techniques
Simple mallet assembly process
Tips and tricks for a professional finish
Tools:
Table Saw - DeWALT 210mm DWE7485-XE
Mitre Saw - Ryobi 2000W 254mm Dual Bevel Sliding Mitre Saw
Thicknesser - Makita 304mm Thicknesser
Carbon Blade Scraper - amzn.to/473rvP4
Sanding Block - amzn.to/479lZKY
Metal Detector - amzn.to/470ljI4
Japanese Flush Trim Saw (small) - amzn.to/3tU6mbM
Japanese Flush Trim Saw (large) - amzn.to/4aqtfE9
Digital Level Angle Gauge - amzn.to/3POMr6g

[@zski03]

It's nice to hear another woodworker speak candidly about dealing with depression and the impact it has on your time in the shop.

[@MelbourneMaker]

Thankyou! Yeh, it can be a tricky subject, especially as a bloke. But good to know that you dont always have to be 100%, and that its ok :)

[@fdort3971]

​@@MelbourneMakeryou are brave talking about it!

[@MelbourneMaker]

@@fdort3971 thankyou. Yeh hopefully it helps others.

[@beachthor1]

I didn’t know other ppl were as good at me at getting stressed out about imperfect work. It’s a craft in itself really.

[@MelbourneMaker]

Haha yep. I'm an expert at that part at least 🤣

[@FixitFingers]

That's a fine looking Thwacker Dave. Liking the sneak peeks of the workbench too. I bet that flattening took a while ;)

[@MelbourneMaker]

Thanks sir! Yeh bench has come up well. Will start editing the video soon. I now have the problem of no storage though now the old bench has retired. At least I have plenty on the to-do list haha

[@laneetherington614]

Nice mallet, looks like you need some tool carts, working on the floor gets old after awhile.

[@MelbourneMaker]

Yeh, after the workbench the next build will be a trolley for the table saw that will have some storage under it. My back will enjoy not being on the floor!

[@ClarkeDesign]

Beautiful hand crafted tools are something to behold.

[@MelbourneMaker]

Thankyou! :)

[@adsincairns]

you banged the wedge in with a mallet..... haha. love your video mate.

[@MelbourneMaker]

Haha keen eyes ;) yeh those rubber ones are too soft though!

[@BadAppleWoodwerx]

I’m amazed at the quality and size of pallet wood you guys have down under. Here in the states our pallets are basically 5/8” slats and 1”x2.5” runners. There’s never anything that thick.

[@MelbourneMaker]

Yeh pretty lucky with some of the stuff you can find down here if you forage past all the pine

[@robertstigter9195]

Hey Dave, nice surpise finding your channel on my journy through YT finding plans for my future workbench. Nice job you did here, I subscribed your channel immediately. Please do not edit too much, I like your quiet way of presentation. You must be lucky down under to find such quality of pallets there, here in Germany I would have to pay a fortune for such quality, so 2 x4s would be a better option. Keep going on this way and we will enjoy many excellent hours of tutorials from you. Have a nice weekend and stay safe, Reards from Robert out of Germany.

[@MelbourneMaker]

Thank you for the sub and your kind words! Yeh, I was super lucky to get those pallets from a friend who works in a warehouse. Have an awesome weekend!

[@MadebyShea854]

Lovely work. Looking forward to the bench build video.

[@MelbourneMaker]

You and me both!

[@fathogwoodworking]

Great mallet build. It’s given me the itch to build another. I don’t even use the first one, but that’s it now I’m building a second.

[@MelbourneMaker]

Cheers mate. Yeh was a good little project for a hot day.

[@Endicorp1]

Nice work David. Great to see pallet wood being repurposed into a useful working tool. Keep up the great work mate.

[@MelbourneMaker]

Thanks, will do!

[@NoLumberLeftBehind]

Nice job on the project and video! The best thing I did was build a workbench (even though its not great). I used to cut things on the ground too, killed my knees and back and it takes more time. I'm sure it is on your project list.

[@MelbourneMaker]

Thanks! Yeh just finished the workbench finally after nearly 5 months of working here and there on it. That should be the next video if all goes to plan.

[@josecanyousee56]

I'd be proud of that. Nice work.

[@MelbourneMaker]

Cheers mate!

[@FallingSunAcres]

So i'm working on a mallet right now, and I really wish i hadn't made it solid and attempted to cut the mortise with hand tools. Lots of issues keeping the mortise straight/square! Your solution of leaving the gap looks a LOT easier. New Sub!

[@MelbourneMaker]

Thanks for the sub! Yeh its a nice and easy to do for people like me who are not great with hand tools :) I also really like the look that the different wood types on the head gives. Well done for giving a solid head a crack though!

[@MelbourneMaker]

Also just saw your Pushy Cat Push Stick video haha. Love it. Great voice sir.

[@patrickfee5065]

Great looking mallet! i really love your presentation calm and collected!

[@MelbourneMaker]

Thanks mate :) Really appreciate it!

[@barrymackay760]

Every woodworker should make their own mallet but I swear I saw you use a Bunnings special rubber mallet in the build 😅

[@MelbourneMaker]

Haha! Yes well spotted sir. Its quite a soft rubber mallet weirdly.

[@fdort3971]

​@@MelbourneMakerit's important to have both kinds...the task sometimes calls for rubber or wood.

[@GeneCaralde119workshop]

Get a saw rasp so the woodworker illusion would be complete, lol. Seriously though, saw rasps are awesome in removing a ton of material quickly.

[@MelbourneMaker]

Yeh I've been wanting one of those for a while. Seem to be a bit pricey though where I am, so each time ive gone to get one I have left it.

[@jimrosson6702]

Very cool great job

[@MelbourneMaker]

Thanks!

[@BuiltByChris]

A mallet from a pallet. Although, I'd love to see you make a wooden pallet. 🤨🤣 Great video, love your style. 👍

[@MelbourneMaker]

Thanks Chris! You made it all the way to the end. Ledgend really appreciate it!

[@dougdavidson175]

Nice wee project M8. Take care & stay safe.

[@MelbourneMaker]

Thankyou sir. Life has been a bit crazy so nice o get back out in the garage again. Next video will be a workbench if all goes to plan.

[@EthanBuilds]

I've been there 😄I made my first mallet few weeks ago as well. Looking foward to watch more.

[@MelbourneMaker]

Thanks mate! I'll have to check out your dovetail video :)

[@EthanBuilds]

@@MelbourneMaker Thank you 👍

[@briansbuildsandoutdoors4936]

Nice mallet. I made a mallet a few years ago and beat the absolute snot out of it. It eventually (last year) gave up the ghost and will need to be replaced. Great video. Keep up the good work. All the best.

[@MelbourneMaker]

Thanks Brian! Appreciate the support. Will see how well this mallet holds up to a beating, but should be pretty good for a while.

[@riversidewoodworks]

7:29 ridiculous. The correct angle is 3.5 degrees haha nah just kidding mate. Really enjoying the build so far!

[@MelbourneMaker]

Lucky im usually half a degree off on my cuts ;)

[@MASI_forging]

Outstanding work 😍😍

[@MelbourneMaker]

Thankyou! You are a true craftsman. Looking forward to binge watching your videos!

[@simonr6793]

Considering what you made it from the mallet turned out really good, my only concern is that after using it for a short while, you're going to need to have a grip like a grizzly bear. That handle as good as it is. It looks like you will need to have huge mits on you to keep a hold of it. You had me worried there for a moment when you were using the chisel on the mallet head to remove the sharp edges it actually looks like any minute you was going to be either sticking the chisel into your other hand or at least remove your thumb🫣🤔. Have you considered buying a Japanese wood rasp for shaving down the handle etc🤔 there about £30 to £40 here in the UK, but honestly worth every penny and absolutely great on shaving down wood etc as both sides of the rasp have different removal rates. One side is coarse while the other is heavy removal. As always buddy 💯% 👍 🇬🇧.

[@MelbourneMaker]

Thanks! Yeh I definitely should have made the handle thinner. But that was about as much energy as the 40+ degree day would give me haha! Yeh I've been looking at those rasps. But more expensive down here in kangaroo land though so it's a bit further down the wishlist. I was being super careful with the chisel. Camera angle added a bit more suspense than it deserved 😉

[@andrejwalilko634]

i do love my carbon steel scraper :)

[@MelbourneMaker]

Yeh how good are they! Definitely bats above it's weight.

[@jimwilliams2682]

Nice thumpenwacker!

[@MelbourneMaker]

Oh man, if only I had been intoroduced to them as thumperwackers before finishing this video. Now it shall always be refered to as such haha. Thanks!

[@davidsquires8107]

Great picks on wood pieces. The contrasts in the side pieces, the shim, and the handle all add that extra pop. I'd be curious how well you like the handle shape after you use it a few hundred times.

[@MelbourneMaker]

Thankyou. Yeh I love bringing out the beuty in what most would consider trash. So far ive only used it for 4 big mortices in the bench top, but I should have really spent a bit more time making it a bit thinner. In my defence it was over 40 degrees that day so I was pretty done haha! I do like a chunky handle generally though. The shape is actually nice as it is easy to position, but yes, a bit on the thick side. For a heavy mallet though, its not bad. If it was a smaller one for fine work would definately want it much thinner.

[@Nedswoodworks]

Bloody top Job David, can always do with a pallet whacker aye. And how’s Dainers form, Sold Out 🤦‍♂️🤦‍♂️🤦‍♂️. Have to have a word with him 😂😂😂 Keep up the great videos and woodworking mate cheers ⚓️⚓️⚓️🫡🇦🇺

[@MelbourneMaker]

Thanks Ned. Champion, yeh got onto Dainsey about his supply chain issues haha! Mallet worked a treat to get this workbench finished

[@PriceyBuilt]

That scraper looked like a pretty good substitute for a spokeshave.

[@MelbourneMaker]

Yeh ive been super impresed with it. Wouldnt be as good as a proper spokeshave, but until I get a better sleection of tools, its a pretty good alternative.

[@DamianDArienzo]

Damn big mallet. Might i suggest sharpening your chisels. Using them like you did, you are going to have a serious accident with your fingers in front like that.. Nice build :)

[@MelbourneMaker]

Thanks! Yeh I sharpened my chisel just after doing this mallet. Although now I've cut out 4 big mortises I need to sharpen it again 😂 one of these days I'll find a few more old chisels at a garage sale to add to the collection.

[@trentwalsh8168]

Im from werribee myself!

[@MelbourneMaker]

Always good to meet a fellow local :) Cheers!

[@trentwalsh8168]

@@MelbourneMaker cheers!

[@EugenioMarins]

Dear Sir, I am trying to do the same thing, a mallet, but i am using very old wood taken from the roof of the building i live in. But it's too damn hard! I am having trouble to make the hole, all me chisels cann't cut through the bloody wood! I'm not as determined as you, so i'll try to continue the project at another time... :O) Cheers from Brazil!

[@MelbourneMaker]

Hi mate, benefit of doing it the way I do in the video is no chiseling required as the centre piece is already in two parts before you glue it up leaving the gap for the handle. Hope that helps. Good luck!

[@stevehedges1158]

Great video i made a mallet many years ago out of off cuts of tas oak. Your mallet looks to good to use. Just a quick question does your metal detector pick up the little pieces of wire in the pallet wood that come off the nails. Steve

[@MelbourneMaker]

Hi mate, thanks! Yes for a cheap detector its pretty good at picking up the wire as long as you go over the pieces a bit slower. The end is very sensitive, the edge is a bit less so if you start to go too quickly. Certainly not at the same level as the expencive ones, but for the price its great.

[@stevehedges1158]

Thanks for your quick reply. Steve

[@jamietetrault4517]

Was wondering if you threw a level on your concrete floor since youve got your saw there..

[@MelbourneMaker]

No, my garage being off level is super frustrating, but that side is not too bad. After I finish the workbench I will be making a mobile cart for the table saw, so that will fix up that problem. Nice pick up.

[@MelbourneMaker]

I also just realised you may have ment when im getting the angles on the blade rather than the saw not being flat. I always zero my level from the saw before I chuck it on the blade. Hope that makes sense.

[@capermache]

Very nice! But hang on Mr. Tighta$$ - were those Festool Systainers in the background at 5:05? Not crossing over to the dark side already, are we??

[@MelbourneMaker]

Haha, keen eyes. Yeh I borrowed them from a friend for the workbench build. Explained more in that video ;)

[@capermache]

@@MelbourneMaker Good to have well equipped friends.

[@MelbourneMaker]

@@capermache yeh. I've never liked how they look, however they are such good tools to use. I know a couple of builders so pretty lucky there

[@54mgtf22]

Are they WorkCover approved thongs? Nice result!

[@MelbourneMaker]

Haha, yep they sure are!

[@DaveWrightKB9MNM]

I just want to know how do you get such nice pallets? 😀

[@MelbourneMaker]

Gotta drive past hundreds of crap ones. These two I was lucky to have put aside for me by a mate who works at a factory though.

[@DaveWrightKB9MNM]

@@MelbourneMaker gotcha. I've just started so I am sure i'll come across some nice ones.

[@DaveWrightKB9MNM]

@@MelbourneMaker so I saw a post on Marketplace for free crate wood from shipping heavy machinery. I procrastinated and this past Saturday I drove the 30 minutes to get there. Boy, I was delighted to see all that pristine pine! Not construction grade but square, crisp edges, heavy duty wood! Enough to make a bench, mallet or whatever else! Going back for more this weekend!

[@trentwalsh8168]

I did mine at 3⁰ also and ive made like..... 5 so far.... why do i even need 5??? 😂😂😂

[@MelbourneMaker]

Hahaha! Great minds! I thought 5 degrees to start but then thought is was going to look like too much.

[@trentwalsh8168]

@@MelbourneMaker legit 3⁰ is ideal. I think..... i think thats what google told me hahaha

[@MelbourneMaker]

@@trentwalsh8168 oh brilliant! Finally a lucky guess! Thanks ;)

[@thecrazysaint]

Your comment about depression getting board and leaves was hilarious!

[@MelbourneMaker]

@@thecrazysaint cheers ;)