Woodworking Mallet Plans

Woodworking Mallet Plans

Woodworking Mallet Plans

Woodworking Mallet Plans

Woodworking Mallet Plans. Constructing a wooden mallet can be an exciting project for woodworkers of any skill level. Crafting something yourself is an incredible sense of achievement that provides both an everyday tool and personal satisfaction.

Mortise and tenon joints connect the mallet handle with its head for precise striking without glue being required. This design makes precise striking possible without needing extra adhesives.

Woodworking Mallet Plans The Handle

Handles for wood mallets can be easily made on either a lathe or by hand, with either process being fairly straightforward and accessible even to novice woodworkers. Handles can be as intricate or basic as desired by their creator, with four pieces of stock glued together into a tapered mortise and tenon joint; this method makes joinery simpler than using thick pieces of wood to build mortises while also eliminating an impractically thick handle from being needed as handles.

To construct the head, a large slab of hard maple should be used; oak or other similar wood may also work. To avoid cracking that could occur with cross-grained pieces that have been steamed for turning, the head must first be cut to size and its angles reduced by 7 degrees before its corners are rounded to protect user from possible splinters.

The handle is also carefully designed, featuring a slight taper from its top end down towards its point of attachment to the head, to enable snug wedgeing into its eye of the head and provide maximum strength and durability. At its end point is smooth sanded finish for added smoothness.

Before the handle is attached permanently, it should be cut to its ideal length and sanded down until it reaches a smooth surface with no sharp corners or protrusions. This will make it more comfortable to hold and less likely to break from pounding on hard surfaces using the mallet.

When creating the handle, the last step involves applying glue to the inside of the head’s mortise and inserting a tenon. After this step is completed, gently hammering will help spread and lock in place the glue and the tenon, before it can be sanded flush for finalization using a round file for any remaining wood inside of the handle.


Wood mallets require both force and finesse when creating one from scratch. While mass-produced wooden hammers may be available, crafting one yourself is truly rewarding experience. Any woodworker with basic tools and wood can create one both durable and attractive wooden mallets to use in short and sharp strikes to wooden workpieces needing some thump, as well as other woodworking tasks like chopping, shaping, and drilling.

A wooden mallet must be constructed from hard, dense wood that can withstand repeated blows without cracking under pressure. The head of such a tool can either be formed out of one piece of lumber or several that are joined together, with the most popular option being hickory but other medium-density hardwoods such as beech or birch being popular options among woodworkers. No matter which material it’s constructed from, its head must always be tapered in order to strike woodworkers’ work squarely against.

Making a wooden mallet requires two distinct steps; first is creating the tapered eye in its head; this may be accomplished using one piece of wood that is cut and shaped as needed, or using multiple pieces that need to be assembled glued together – Popular Woodworking features an example project using this latter approach – both can be accomplished more easily using modern woodworking equipment.

Once the head has been shaped, it should be sanded to smooth its contours and radiuses of all surfaces. Sanding should typically be completed using an orbital sander with variable speeds that allows woodworkers to control how fast sanding progresses.

Once sanding has been completed, both parts can be assembled. Before applying glue, both parts should be thoroughly checked for flatness using a straightedge or square and bright backlight to identify any cupping, waviness or other defects that would compromise the quality of their finished product.


Wooden mallets feature handles secured to their heads by wedged mortise and tenon joints, typically used to attach heavier tools. While this method works great for mallets too, ensuring that their handle does not slip off or break during use. Plans available online show you how to properly cut wedges that secure their handle to the mallet head – making this project an excellent opportunity to practice your woodworking skills while creating something truly special that any woodworker would appreciate!

Wood mallets are typically constructed of hardwood such as beech, hickory or birch; however, woodworkers may use any medium-density type of wood that won’t damage wooden workpieces when struck with it. No matter what material it’s constructed from, each wooden mallet often boasts its own distinct shape and feel that owners love.

When choosing the type of wood for crafting a mallet, it is essential to think carefully about its intended use. A wood carver’s mallet may require softwood while joiner or brass mallets should be made out of hardwood. Furthermore, one must consider how the wood will be stored before use; does it need to be kilned to reduce moisture content?

One of the more innovative mallet designs comes from iBuildIt, using an innovative twist on traditional wedged mortise and tenon joints to reduce heavy chisel work and make joint creation simpler.

Crafting a wooden mallet may seem easy, but it is crucial that you take your time and pay close attention to detail. Rushing this job may result in inaccurate measurements that lead to unusable products. While sanders may help smooth over rough edges of handles, for maximum comfort it is advisable to hand sand any sharp spots that might cause discomfort during use.

No matter whether it’s your first wooden mallet or creating an entire shop’s worth of mallets from various species of wood, selecting an attractive grain pattern and natural coloration is key to creating beautiful designs. Different wood species each offer their own distinct grain patterns and markings that add character and uniqueness to each finished mallet design.


Wood mallets can be an indispensable tool for practicing spindle turning, as well as serving as an excellent hammer to strike blocks or pieces of wood together. Professional woodworkers often prefer solid beech, while any medium-density hardwood works. Crafting wooden mallets may seem straightforward, yet exact measurements and an eye for detail must be considered for creating one successfully. Swinging the mallet will wedge its head into place, and every strike strengthens this bond further.

As the first step of creating a mallet, you need to select an appropriate wood. Medium-density hardwood such as walnut or maple are often recommended because of their weight and durability, although decorative wood such as cherry or curly maple may provide more beautiful designs. Once selected, sand away any defects and roughness before cutting the mallet head shape that fits you best; its size should roughly correspond with that of its slot in the handle while being free from knots – you could also chamfer its edges for aesthetic purposes or extra strength!

When cutting your mallet wedge, be sure to create a rounded edge that won’t scratch or mark wooden workpieces. A round rattail file or scrap piece of wood with a rounded notches sawn out will work well here.

Once your wedge has been formed, sand it to match the thickness of its handle and apply wood hardener as needed to protect it against future damage.

Woodworking plans available online typically call for beechwood as the handle material and walnut as the head material for mallets, although any medium-density wood will do – as long as it does not damage wooden workpieces when struck with its head. Some plans recommend gluing the handle directly to its respective head while others use wedge designs that keep both securely attached.