RocketScientist, inspiring and impressive. I look up to you, good sir.
Steps 2-5: Preparing the Shaft
Steps 6-7: Preparing the Core
Step 8: Assembly
Steps 9-12: Wrapping
Step 13: Repeat steps 2-12 three more times
Step 14: Evaluation
Step 1: Materials and Tools
-Wooden dowel, ideally, birch or rattan but it can be hard to come by. I used 9.5mm Tas Oak. I believe most commercial mallets are 8mm. You'll need enought, obviously, for however many mallets you are making. Generally, 40cm mallets are good, so a 0.8m or 1.6m length would be ideal for 2 and 4 mallets respectively.
-Chair tips, the things you put on the ends of legs of chairs to stop them skidding. I think I used 19mm size, leftovers from the cajon project. Anything much over 19mm will result in a mallet way to large. I used rubber, plastic ones would give a different tone.
-Larger wooden dowel, to fit in the chair tips.
-Yarn, Wool or Cord, there are no real definitions here, I used thin 4ply wool
-Glue, I just used PVA, you could use epoxy or whatever you feel is strongest.
-Small saw (or large, it doesn't really matter I guess)
-Sandpaper, fine and coarse
-Drill/Drill press (not pictured)
-> Drill bit the diameter of the shaft (not pictured)
-Tape Measure/Ruler (not pictured)
-Safety gear - glasses, ear protection, etc. (not pictured)