Carpenter's Mallet

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Project by PioneerRob posted 02-12-2014 04:31 AM 9646 views 10 times favorited 10 comments Add to Favorites Watch

It’s time for a new mallet. I usually turn my own round mallet, and figured it’s time for a change.

I made this out of birch, for no reason other than it’s what I had on hand. I bought a few boards some time ago for a project that I never did, so I have lots.

I’m thinking that birch isn’t the best choice. It’s brittle and chips easily; probably not the best quality for a mallet. But we’ll see.

I was aiming for 16 oz, and ended up at 15.8 oz. Not bad.

1. Finished mallet.
2. Rough sawn handle.
3. Head parts before gluing.
4. Head glue up.
5. Handle shaping.
6. Rough mallet before finishing.


-- Rob, Ontario

10 comments so far

View NuclearGrade's profile


40 posts in 2811 days

#1 posted 02-12-2014 05:43 AM

Great design and construction as well. I want to build one soon.

-- Dan Wilson - Red Wing, MN

View Greg D's profile

Greg D

238 posts in 3160 days

#2 posted 02-12-2014 06:00 AM

Nice job, I need a new one myself!

-- Greg D, Cen. CA, "Keep it on the Level, Do it Right the First Time!"

View Ken90712's profile


18058 posts in 4398 days

#3 posted 02-12-2014 10:20 AM

Nice work, I have made few of these as well. fun project and saves money for other things….Great job.

-- Ken, "Everyday above ground is a good day!"

View 489tad's profile


4041 posts in 4220 days

#4 posted 02-12-2014 02:14 PM

A great looking mallet. Maybe if you put leather on the faces it will help prevent splintering.

-- Dan, Naperville IL, I.G.N.

View woodbutcherbynight's profile


10239 posts in 3618 days

#5 posted 02-12-2014 04:27 PM

+1 489tad leather on the ends works well.

Nice project the pictures showing the stages were especially helpful so thanks for that extra touch I am off today so maybe I will get out in the shop and get cracking…

-- Live to tell the stories, they sound better that way.

View Eddie_T's profile


237 posts in 3280 days

#6 posted 02-12-2014 07:20 PM

I have been hoarding scraps for years. I recall a FWW article or tip in the distant past on this type of mallet build. You did a nice job and have kindled a spark in me to get moving. Your pic 3 showed me that getting a proper fit to the handle taper need not be a problem.

View Richard's profile


11310 posts in 4242 days

#7 posted 02-12-2014 10:43 PM

Nice Project Indeed Rob! Nice to see that it’s also a Left Handed Model for Guys Like Me! ...LOL..

Thanks For Sharing.


PS: I use to live in Peterborough for a few years …Long Time Ago. I see Roland’s Steak House is still there. YUMMY!!!

-- Richard (Ontario, CANADA)

View Karson's profile


35278 posts in 5609 days

#8 posted 02-13-2014 12:29 AM

Our woodworking club is going to have a workshop on making mallets in a month or so. I picked up a persimmon board a years ago and I might use it, But looking at the chart of wood hardness, one of the hardest and easy to get ahold of is Ipe. It’s available as desk board in the USA. I found a piece of it in my shop but it’s about an 1 1/2” thick by maybe 3”. It might make a nice compact mallet for using on chisels.

I just measured it it’s 1 1/8 X 2 1/2 and man is It hard.

-- 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 PioneerRob's profile


47 posts in 2821 days

#9 posted 10-29-2014 02:16 PM

Thanks for all the comments.

Unfortunately it was doomed to fail. Early in the summer, when whacking a holdfast, the head flew apart at the glue joint. It appeared that I hadn’t aligned the faces properly, and put a lot of stress at the glue face because the grain directions were perpendicular.

I wouldn’t recommend this approach to making a mallet.

No matter. I found some nice ash this fall and will soon post the mallet 2.0.

-- Rob, Ontario

View woodbutcherbynight's profile


10239 posts in 3618 days

#10 posted 11-02-2014 04:01 PM

glue and screw????

-- Live to tell the stories, they sound better that way.

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