Crafting a Wooden Mallet from Scratch

Article 25: Crafting a Wooden Mallet from Scratch

By: A Woodworker Who Believes Every Tool Deserves a Story

A wooden mallet is a must-have for joinery and chisel work. Making your own adds character to your bench and teaches precision skills.

Materials List

ItemQuantityHard maple (head)1 block, 6”x3”x3”Oak (handle)1 piece, 12”x1.25”x1.25”Wood glueAs neededBoiled linseed oilSmall bottle

Tools Needed

• Bandsaw or handsaw

• Drill with Forstner bit

• Wood rasps and files

• Clamps

• Mallet or hammer

• Sandpaper (80–220 grit)

How-To Steps

1. Shape the Head
   Cut the head block to size. Drill a mortise (1.25" square) centered on one face, 1.5" deep.

2. Cut the Handle
   Shape the handle with a tapered end (1" at top, 1.25" at base). Use rasps for ergonomic grip.

3. Join and Glue
   Fit the tapered handle into the mortise. Use glue only at the base of the mortise to allow slight flex.

4. Finish
   Sand smooth. Apply boiled linseed oil to bring out the grain and seal the tool.

Visual

[Side View]
    Handle
      │
     ╱╲
    ╱  ╲
   │Head│  ← 6"x3"x3"
   └────┘