Mallet Faces

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Project by TerryDowning posted 03-24-2014 04:23 PM 1559 views 0 times favorited 5 comments Add to Favorites Watch

While waiting for finish coats to dry on the Treasure Box and Cherry Box finished up this weekend, I replaced the faces on my plastic tipped mallet. While researching replacement faces, it was suggested that I make my own. These were turned on my lathe and were surprisingly simple to do.

I had some 2 ” Maple left over from a bowl I turned it round between centers marked out as many faces as I could with a parting tool. Drilled on end with a 1/4 ” drill so a 5/16×18 bolt could be screwed into place. Bolt was cut to length and held in my drill chuck for final turning to diameter and the little step that goes inside the head.

I managed to get 5 faces turned from Maple and one additional face from a scrap of delrin I had laying around. Time will tell how these turned out.

-- - Terry

5 comments so far

View Woodknack's profile


13522 posts in 3298 days

#1 posted 03-24-2014 05:15 PM

Cool looking mallet. So do the faces just screw in?

-- Rick M,

View TechTeacher04's profile


458 posts in 2450 days

#2 posted 03-24-2014 05:16 PM

You might want to make one out of a softer material. The benefit of the rubber mallet is that you will not mar the surface of your board. Maple heads will almost assuredly be harder than the work pieces you are using.

View TerryDowning's profile


1146 posts in 3035 days

#3 posted 03-24-2014 05:18 PM

I have some pine scrap. Now that I know how easy these are to make, I can pretty much use any material available. The maple is actually pretty soft as I recall.

-- - Terry

View CFrye's profile


11109 posts in 2758 days

#4 posted 03-24-2014 11:33 PM

Big improvement Terry! Handle next?

-- God bless, Candy

View TerryDowning's profile


1146 posts in 3035 days

#5 posted 03-24-2014 11:37 PM

Thanks Candy.

No plans for replacing the handle until it’s far worse. It’s still doing the job, so I’m leaving it for now. The faces were pretty much done though. After 40+ years (at least. I’ve used this hammer my entire life and don’t ever remember it being different until now.) it was time.

-- - Terry

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