Plywood Mallets

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Project by Jim Jakosh posted 05-18-2013 11:57 AM 4652 views 24 times favorited 44 comments Add to Favorites Watch

I had this project in mind ever since Mads said he saw a plywood mallet in Paris. I wondered what it would look like with the head and handle all made from plywood. So, I laid up 4 blocks and cut some maple for the faces.

They is maple plywood with solid maple faces that are glued in with a 1” dia. tenon. I wanted the grip to be more “hand shaped” so the grip area is oval. I turned in on three centers that were in a hardwood piece on the end. I was afraid the centers that close to each other in plywood might break away.
They came out pretty good with the grain of the plywood accented with every high spot turned on the pieces.

They are 10” long and the heads are 2 1/8” dia. and 5 1/2” long and finished with clear matte spray.

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

44 comments so far

View HorizontalMike's profile


7933 posts in 4157 days

#1 posted 05-18-2013 12:14 PM

OK,great! I was going to comment on the lack of impact resistance with plywood, HOWEVER you have addressed that very concern nicely with hardwood head-tips. Cool! Another lathe project to consider… 8-)

-- HorizontalMike -- "Woodpeckers understand..."

View MShort's profile


1798 posts in 4661 days

#2 posted 05-18-2013 12:31 PM

Neat designs for the mallet. I had the same thoughts as H-Mike, till I saw the hardwood as well.

-- Mike, Missouri --- “A positive life can not happen with a negative mind.” ---

View Diggerjacks's profile


2330 posts in 4382 days

#3 posted 05-18-2013 12:33 PM

Hello Jim

A good idea and a very nicely work

The contrast is beautiful
An idea that will be tested in the future
Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View harry1's profile


537 posts in 3528 days

#4 posted 05-18-2013 12:40 PM

I’m astounded at the that you’re “turning” out these wonderful items Jim, you are quite amazing.

-- Harry, Western Australia

View HillbillyShooter's profile


5811 posts in 3535 days

#5 posted 05-18-2013 12:51 PM

Very interesting design and a noval design—certainly NOT “just another mallet.”. Attractive and well thought out, especially the solid maple faces! Know you’re glad you got your lathe fixed. Thanks for sharing.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View doubleDD's profile


10703 posts in 3286 days

#6 posted 05-18-2013 12:56 PM

Beautiful job Jim. Great way to display the EYE of the plywood. Reminds me of a totem pole I made as a joke out of elm to scare off evil spirits. Keep them coming.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View sedcokid's profile


2738 posts in 4842 days

#7 posted 05-18-2013 01:04 PM

Jim, Nice look’in project my Friend!! I like the look of the plywood, do you have any problems with tearout or any other issues? Your work always looks great and I appreciate your comments too.

Thanks for sharing…...

-- Chuck Emery, Michigan,

View wiswood2's profile


1138 posts in 4939 days

#8 posted 05-18-2013 01:40 PM

Real, nice looking mallets.

-- Chuck, wiswood2

View Tooch's profile


2016 posts in 3119 days

#9 posted 05-18-2013 01:42 PM

Those look really sweet. were you able to turn all of the solid maple heads on one piece? or did you make each separately?

Nice job, nice job!

-- "Well, the world needs ditch-diggers too..." - Judge Smails

View stefang's profile


17040 posts in 4577 days

#10 posted 05-18-2013 01:49 PM

Beautiful mallets Jim and unique too.

-- Mike, an American living in Norway.

View shipwright's profile


8751 posts in 4041 days

#11 posted 05-18-2013 01:53 PM

Sweet !

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View BusterB's profile


2365 posts in 3251 days

#12 posted 05-18-2013 02:03 PM

Very unique look you have managed to craft there Jim… What can I say but…..AWESOME

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View Knothead62's profile


2600 posts in 4204 days

#13 posted 05-18-2013 02:27 PM

Outstanding! What turning tools did you use? Have a lot of scrap plywood that needs to be made into something. Thanks for sharing.

View tyvekboy's profile


2132 posts in 4256 days

#14 posted 05-18-2013 03:11 PM

Very Interesting. Thanks for sharing

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Ivan's profile


17010 posts in 4111 days

#15 posted 05-18-2013 03:12 PM

You are doing amaizing things with playwood!

-- Ivan, Croatia, Wooddicted

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