Mallet Craze

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Project by Tom Pritchard posted 03-19-2014 08:02 PM 2167 views 3 times favorited 13 comments Add to Favorites Watch

I’m always looking on line at all the great You Tube websites of all my favorite woodworkers and awhile back I was watching Brian Grella on his “Garage Woodworks” website. I was very interested in making one of his mallets to use with my wood carving. Watching his simple straight forward method of teaching I was very successful. Actually I made some mistakes that forced me to start over, but it was worth the effort.

I used walnut and oak as my two main wood selections. In the handle part I started out trying to hand carve a basket weave look on both sides of the handle. As some know trying to hand carve oak is really tuff. After completing the carving I was not happy so I routed out the carving and inserted two walnut inserts. I wish I would have selected a darker piece of walnut, but since this tool will get beat around, I was not too concerned.

Overall I’m very happy with the results. I’m hoping that I will get much use as one of my main carving tools.

-- Tom in Mount Vernon, Wa

13 comments so far

View kiefer's profile


5802 posts in 3554 days

#1 posted 03-19-2014 08:54 PM

That will do just fine and the walnut is a nice accent too.
As long as it is built solid it will last for years .

-- Kiefer

View bit101's profile


106 posts in 2764 days

#2 posted 03-19-2014 10:06 PM

Nice. What are the dimensions?

View Tom Pritchard's profile

Tom Pritchard

188 posts in 3579 days

#3 posted 03-20-2014 01:45 AM

hey bit 101,
Here is the finished dimensions. The head is 2.5 inch square x 5.25 inches long. the handle is 1 inch square x 11.50 long. These are the finish length of handle. You would want to make about 1/2 inch longer to cutoff after assembled. If you are interested I would be glad to make a shetchup drawing and send your way if interested. Thanks for commenting.

-- Tom in Mount Vernon, Wa

View bit101's profile


106 posts in 2764 days

#4 posted 03-20-2014 02:53 AM

I’ve already got a mallet in progress with some scraps I had lying around. A bit smaller, I think 2.5” square x 4.5 long and the handle is about 10.5 if I recall correctly. Did you add weight to it to make it a deadblow mallet? If so, can I ask what you used and where you got it? I’ve been looking at lead fishing weights and bbs. Not sure what is best.

View Tom Pritchard's profile

Tom Pritchard

188 posts in 3579 days

#5 posted 03-20-2014 11:19 AM

Hello bit101,

I used “BB’s” The idea came from the link I show above in my project description above. I made my mallet based around that video. I’ve heard of using fishing weights or shot. The BB’s seem to give it a good feel. Per my mallet, I feel like the weight feels good.

-- Tom in Mount Vernon, Wa

View NickyP's profile


180 posts in 2611 days

#6 posted 03-20-2014 12:43 PM

Hi Tom . . . VERY nice mallet sir. WELL DONE! I came up with this and just may incorporate the leather string idea. I will be stain the handle of mine yellow to make it stand out, leaving the head natural and finishing it with some Birchwood Casey Tru – Oil Gun Stock Finish. And . . . I will be making a replica of yours as well. Thanks for the fine project!

-- -- "Never underestimate the power of a kind word, a good deed, or a table saw."

View bit101's profile


106 posts in 2764 days

#7 posted 03-20-2014 02:24 PM

Thanks Tom. Yeah, I saw that video. There seemed to be a flurry of mallet making a few weeks back. I’m using the same rough plan myself. Got all the pieces cut and holes drilled. Now off to find some BBs.

View bit101's profile


106 posts in 2764 days

#8 posted 03-20-2014 06:30 PM

BBs acquired. Mallet head glued and clamped. Thanks for the info!

View Richard's profile


11310 posts in 3920 days

#9 posted 03-21-2014 06:32 AM

YEA! A Left Handed Mallet! Very Nice! & Well Done! Thanks For Posting.

-- Richard (Ontario, CANADA)

View JSB's profile


737 posts in 2966 days

#10 posted 03-21-2014 03:50 PM

Great looking mallet tom!

-- Jay -

View Tom Pritchard's profile

Tom Pritchard

188 posts in 3579 days

#11 posted 03-21-2014 03:58 PM

Thanks Jay..

-- Tom in Mount Vernon, Wa

View Roger's profile


21030 posts in 3691 days

#12 posted 03-22-2014 12:25 AM

Nice mallet. These are handy dandy to have, and to make.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View thelt's profile


671 posts in 4267 days

#13 posted 03-23-2014 10:19 AM

Nice looking mallet, Tom!!! Bit101, Tom & NickyP, I finished mine up last night, except for the finish, that I’m going to do today (a couple of coats of BLSO). I didn’t think of the leather thong to hang if by. I just may drill a hole in the handle just in case and then put the finish on. If Anybody wants the plans they are in ShopNotes #2 March 1992. The plans call for lead split shot, I used BB’s @ $4.57 from Wal-Mart. The price of lead split shot (fishing weights) was twice that or more. Again great job.

-- When asked what I did to make life worthwhile in my lifetime....I can respond with a great deal of pride and satisfaction, "I served a career in the United States Navy."

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