Super Mallet

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Project by Jeff Farquhar posted 01-03-2016 04:37 AM 3328 views 2 times favorited 3 comments Add to Favorites Watch

Having some leftover walnut from a side table that I made, I decided that it was time that I make my first wood mallet. For having no game plan other than “need mallet, build mallet”, I couldn’t be happier with the results!

First, I cut the taper into the sides of the top of the handle to help hold the head securely to the handle. Based on what I had on hand, the easiest way I could think of for me to do this was to cut a series of kerfs into the handle then chisel out the waste. I then cut the angles on two blocks to go on either side of the handle (the middle layer of the head). Next, I glued the two blocks onto one of the outer layers of the head. Of course, I forgot to drill out the holes that would eventually hold the fishing weights before I glued them together, but no harm done, I was able to drill them out once the glue was dry. While the glue was drying, I put the handle on my lather and turned the middle portion of of the handle just enough to round over the edges. After the glue was dry and the weights were added, I glued the handle and the final outer layer together with the rest of the head. For added durability, and looks, I put two oak dowels through the top and bottom of the center of the head so that they would go through the top of the handle. Once assembly was complete I chamfered all the edges of the head.

I was pretty happy with it at that point but decided that I wanted to carve something into both sides of the head. I eventually carved my family name into one side and the Scottish flag (sadly, no color though) into the other. I used my Dremel rotary tool to carve both designs.

Once I was happy with the look of the carving, I applied Danish oil (natural) to the whole thing. All that’s left is to add leather patches to both faces. My plan is to glue the leather on with E6000. As this is the first time I’ll be glueing leather to wood, I’m all ears if someone has a better method.

Thanks for taking a look.

3 comments so far

View TheFridge's profile


10859 posts in 2000 days

#1 posted 01-03-2016 04:57 AM

I don’t know what e6000 is but if it’s epoxy it should work like a champ.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View WistysWoodWorkingWonders's profile


12785 posts in 3671 days

#2 posted 01-03-2016 06:09 AM

nice work, love the carving details in this one… thanks for posting the in progress pics, nice to see how you combined everything…

-- New Project = New Tool... it's just the way it is, don't fight it... :)

View drobertson's profile


57 posts in 3631 days

#3 posted 01-07-2016 12:57 AM

Nice work on your first mallet. Watch out, it can get addicting.

I always thought that a turquois inlay would be perfect for the scottish flag. I would recommend that, but I don’t think it would survive on a mallet. Too much stress.

Keep up the good work.

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