How to Make a Wooden Mallet from Scrap Wood
Every woodworker has a collection of hardwood scraps that are just too good to throw away. Here's a practical project that puts some of those leftovers to work. With a few strips of hardwood and some basic woodworking tools, you can build a custom wooden mallet that's as attractive as it is useful.
In this video, Woodsmith designer John Doyle shows how to make a shop-built wooden mallet with a laminated head and a comfortable, contoured handle. The project originally appeared in ShopNotes magazine and is a great way to turn small pieces of hardwood into a tool you'll reach for again and again.
Building a Laminated Wooden Mallet
The mallet head is made by gluing together thin strips of hardwood. For this version, John combines light-colored European beech with dark wenge to create a striking contrast.
Rather than laminating the entire head at once, he builds it in stages. This makes it possible to cut the mortise for the handle at the table saw using a dado blade before adding the remaining layers. It's a simple approach that eliminates the need to chop a deep mortise by hand.
The head also includes metal weights concealed inside the laminations to give the mallet some additional heft.
Shaping the Handle and Assembling the Mallet
The handle starts as an oversized hardwood blank. After cutting the tenon that fits into the mallet head, John shapes the handle using a pair of shop-made router templates.
The templates make it easy to create consistent curves on all four sides. A roundover bit then softens the edges for a comfortable grip.
Finally, the handle is glued into the head and secured with hardwood wedges. A tung oil finish brings out the contrasting grain and provides a little protection.
The result is a durable, well-balanced woodworking mallet that's useful for tapping joints together, assembling projects, and working with chisels.
Get the Wooden Mallet Woodworking Plans
Ready to make one for your own shop? The downloadable Woodsmith plans provide the dimensions and construction details for building your own shop-made mallet.
It's a rewarding weekend project and a great way to use some of those hardwood scraps you've been saving.
GET THE STEP-BY-STEP WOODWORKING PLANS → Build a Scrap Wood Mallet
For a limited time save 25% all woodworking plans with by using Coupon Code: TOOL at checkout.
Types of Woodworking Mallets: Uses & How to Choose
From driving chisels to assembling furniture, different woodworking mallets are designed for different tasks. Learn how mallet shape, weight, and materials affect performance so you can choose the right one for your shop.
EXPLORE WOODWORKING MALLETS → Choose the Right Mallet for the Job
