• Advertise with us
Project by PurpLev posted 08-15-2010 11:05 PM 5805 views 18 times favorited 27 comments Add to Favorites Watch

Pallet to Mallet,
a Mallet from a Pallet.

I needed one for a very long time as I always seemed to be using the closest available heavy block of wood for chisel work. I ended making this one from a single Oak pallet slat that had some nice figure to it.

head is 3”x5”x~2.5” – laminated 4 layers
handle is 1 1/4x~1 1/4”x as long as I could have it (for balance). It’s ~16” long (through the 3” head)-laminated 2 layers

The handle is not glued to the head, but is wedged in. the inner parts of the head are cut at 2° on each side, and a wedge with edges at 4° once pounded in (with glue) presses the handle tight into the head, while also keeps it from moving with the now wedged/slopped handle top – its basically locked in.

The head faces are both cut at 1° slope to follow the direction of the blow better.

finished with 2 coats of BLO.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

27 comments so far

View jack1's profile


2172 posts in 5524 days

#1 posted 08-15-2010 11:18 PM

Looks like a good mallet. It does have a good figure.

-- jack -- ...measure once, curse twice!

View Lenny's profile


1752 posts in 5024 days

#2 posted 08-15-2010 11:29 PM

That’s a great save Sharon. Pallet to mallet indeed. Instead of being in a landfill, this oak will be helping you make fine projects.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View littlecope's profile


3157 posts in 4999 days

#3 posted 08-15-2010 11:47 PM

Good Looking Mallet, Sharon… Being Oak, that must have some nice heft to it…

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View Gary Fixler's profile

Gary Fixler

1001 posts in 4878 days

#4 posted 08-16-2010 12:20 AM

Very nice! I might like to follow along with my own mallet one of these days. I have a lot of pallet wood here.

-- Gary, Los Angeles, video game animator

View PurpLev's profile


8654 posts in 5145 days

#5 posted 08-16-2010 12:24 AM

Thanks guys,

Mike – as for the heftiness. I was surprised by how light it felt once I got all the parts cut out for it. not that it’s light – but I guess I was expecting it to be heavier. it does good though – it has a very balanced feel to it both in total weight, and in head-to-handle balance.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View ellen35's profile


2750 posts in 4929 days

#6 posted 08-16-2010 12:41 AM

Very cool, Sharon!
I love the price!!

-- "Don't let the perfect be the enemy of the good." Voltaire

View David's profile


172 posts in 4339 days

#7 posted 08-16-2010 12:41 AM

nice looking mallet. Even if the heft is not what you were expecting, the long handle will give you the leverage you need.

-- “Don’t tell me what can’t be done, tell me what you want done then shut up and get out of my way and let me do it!”

View Karson's profile


35301 posts in 5897 days

#8 posted 08-16-2010 01:20 AM

Very nice Sharon. A great use of recycled materials.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View PurpLev's profile


8654 posts in 5145 days

#9 posted 08-16-2010 01:35 AM

Dont get me wrong folks – it’s hefty enough :) I guess my point was more that I thought it would just be heavier – which I am glad it’s not since that would put unnecessary strain on me.

As for recycling materials – I originally had mighty plans for these pallets for some outdoor projects, and milled/laminated boards together to get thicker boards that I can actually work with. it took 9 slats and 1/4qt of glue to make 6 1.5”x1.5”x40” boards and 1/2 a day of labor – all in all, I am still not sure the electricity use, planer blades (adding total usage) and the time would qualify this as being green. But thats what I have to work with, and so far so good.

This mallet on the other hand only used 1 slat, and minimal labor – so I would definitely consider this one green!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View SPalm's profile


5338 posts in 5379 days

#10 posted 08-16-2010 01:54 AM

Looks like a good wacker.
How did you attach the head? You say it is laminated, so I can guess…


-- -- I'm no rocket surgeon

View Lee A. Jesberger's profile

Lee A. Jesberger

6883 posts in 5476 days

#11 posted 08-16-2010 02:19 AM

Hey Sharon,

Nice mallet pallet!


-- by Lee A. Jesberger

View moonls's profile


412 posts in 4483 days

#12 posted 08-16-2010 02:29 AM

Good work Sharon! Many of my projects are made from recycled wood. I hate too see good wood go to waste!

-- Lorna, Cape Cod

View PurpLev's profile


8654 posts in 5145 days

#13 posted 08-16-2010 03:44 AM

Steve – I uploaded 2 more pictures to show you the attachment of the head – it has nothing to do with the lamination – although since all the parts come from a single board, it was easier to get a perfect fit in thickness. that aside – the construction is just a standard wedge with edges at 4° to one another. the center head-blocks inside are cut at 2° on each side, so that the wedge will create a perfect fit between all parts inside and eliminate gaps once pounded in.

since the head and handle grain go in perpendicular direction – I’m not sure it would be wise to otherwise glue the head to the handle – which again was another reason I chose the wedge method.

The mallet head front and back (end grain parts) are cut at 1° slope.

Lee – when all else fails – I can always use the mallet to ship merchandise :)

Thanks Lorna – I know exactly what you mean about seeing good wood go to waste. and hardwood pallets usually have a high percentage of good usable material. only thing is – it takes some work to get it to a usable state :)

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View swirt's profile


7795 posts in 4469 days

#14 posted 08-16-2010 03:50 AM

Nice mallet and thanks for including the x-ray view form Sketchup. ;)

-- Galootish log blog,

View PurpLev's profile


8654 posts in 5145 days

#15 posted 08-16-2010 03:58 AM

glad it’s helpful swirt

FYI: I just drew the SketchUp model now to illustrate how I built the mallet earlier (using my BoardMaker plugin by the way ;) ).

-- ㊍ When in doubt - There is no doubt - Go the safer route.

showing 1 through 15 of 27 comments

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics