Joinery Mallet

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Project by D. B. posted 10-24-2020 09:42 PM 568 views 0 times favorited 8 comments Add to Favorites Watch

This is a basic woodworking mallet useful in joinery and chisel work. I started with a salvaged piece of hardwood. The species is unknown to me. I cut the head to shape, resulting in tapered faces and a slightly rounded top. Then I marked layout lines for a tapered handle. The waste for this mortise was removed with an auger bit in a brace. Next I chopped the mortise, keeping the lines in the top and bottom openings parallel as I crept up on the layout lines. A tapered handle was made out of oak: 1 1/2” at the top, 1 1/14” at the bottom, 15 inches long. I planed the handle square and smooth, with chamfered edges on the gripping surfaces. The mallet head was shaped by adding curved chamfers on the main edges and 45* chamfers on the striking faces. I finished it with boiled linseed oil. Two pieces of wood, properly shaped and joined with one mortise, become a very functional and useful tool. It has great balance when the mallet is gripped up under the head. But it has powerful striking force when the grip is moved nearer the bottom of the handle. Fun project for me.

8 comments so far

View metolius's profile


260 posts in 1642 days

#1 posted 10-25-2020 01:24 AM

Great mortising – Nice !

-- derek / oregon

View siemensgeek's profile


49 posts in 119 days

#2 posted 10-25-2020 02:28 AM

Good work! I’ve made one mallet so far but it won’t be my last. They are really fun to make and I love using a wooden mallet. My wife thought I was nuts because after I finished mine I carried it around whacking stuff for days. I think she thought I was going to do her in.

My problem is finding suitable blocks of hardwood here on the high plains of Texas. I’ve got an old Maple headboard in my storage building with square posts that are large enough to make a mallet head. I hope my Grandmother will forgive me.

-- Greg, Amarillo quote - 'Tis dangerous meddling with edge-tools. ~John Tatham, c.1652

View Tom's profile


156 posts in 803 days

#3 posted 10-25-2020 02:06 PM

Nice work! The contrasting wood is nice.

-- Tom

View grovemadman's profile


744 posts in 4683 days

#4 posted 10-25-2020 03:43 PM

I just made one myself from a Eucalyptus log a customer was going to burn in their fireplace. Very useful and I’ve been using mine like crazy! Nice job and happy woodworking.

-- "It is the job of the woodworker to hide his mistakes and keep a tight set of lips about them!"--Chuck

View D. B.'s profile

D. B.

33 posts in 2952 days

#5 posted 10-25-2020 04:48 PM

Thanks everyone.

View D. B.'s profile

D. B.

33 posts in 2952 days

#6 posted 10-25-2020 04:49 PM

Nice work! The contrasting wood is nice.

- Tom

FYI I think the contrast is from freshly applied BLO on the end grain. Other photos don’t show quite as much contrast.

View Andre's profile


3821 posts in 2717 days

#7 posted 10-25-2020 11:36 PM

Nothing like the feel of a fresh Mallet in the Workshop:)
for some reason never liked the feel of a square mallet for chisel work?

-- Lifting one end of the plank.

View Hoss24's profile


6 posts in 28 days

#8 posted 10-26-2020 12:33 AM

I need to make one of these. Well done!

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