The most important step in constructing a mallet is choosing a strong, yet light ski pole. Used sports stores, thrift stores, and ski lodges will often have poles for sale; you should pay under five US dollars per pair. To select a good ski pole, use the following steps:
- Measure the length of the mallet from the top of the handle to the top of the basket. Most people use mallets in the high thirty to low forty inch category.
- Check the material - aluminum or steel are good, carbon or bamboo should never be used. Titanium is a toss-up - some people like it, some don't due to its flexibility.
- Check for kinks in the mallet. Scratches are OK, but a kinked mallet is a doomed mallet.
- Test the strength of the mallet by flexing it over a knee. This will take some practice to get a feel for it, but it should take a fair amount of effort to bend the mallet. Too flimsy and it will break quickly.
Tools needed: drill, screw, razor blade, hacksaw, pliers, 2.5" T-nut and bolt, desired wrapping material.