Introduction: Pallet Mallet

Picture of Pallet Mallet

I needed a wood mallet and kept forgetting to grab one at the store, so I made one. My buddy casey gave me some red oak pallets and they had been sitting in my woodshop (garage) for several months now. I figured I would try to make one from that wood.

Step 1: Preparing the Wood

Picture of Preparing the Wood

Remove any nails and thickness plane the boards. The board started at 1" thick by the time I was done the final thickness was 3/4 of an inch.

Step 2: Lay Out

Picture of Lay Out

I took the wood to my chop saw and started cutting. No real plan here just cut the boards how I thought they should be cut.The head of the mallet will be three boards wide. The outside boards will be one peace 9 inches long. the the center boards will be cut in two each 3.5 inches leaving a gap for the handle.

Step 3: Glue Up

Picture of Glue Up

I glued the boards together and left a 1.75 inch opening in the middle of the block for the handle. So this is the time if you are a friend or family member or a clamp supplier to realize a good Christmas gift this year is wood clamps. I made it work with what I had. After the glue set up I drilled some 3/8 holes for some walnut dowels. I do not think they are necessary it just looks cool. i then cut a 5 deg bevel to the head of the mallet. this also squared up the mallet face.

Step 4:

Picture of

The handle I ripped a peace of the same pallet wood 1.5 inches wide for the handle. I then when went over to my Shopsmith and started turning the handle. I wanted the handle to stick out of the top of the hammer because it looks cool. So I just started turning. I finish sanded the handle to 600 grit.

Step 5: Finishing

Picture of Finishing

I inserted the handle in to the head of the mallet and drove two more dowels in to the mallet head to secure the handle. After this I hand sanded the dowels and passed the complete mallet through the planer to trim the dowels perfectly smooth.  I did about 5 min of hand sanding to 600 grit. I finished the handle with three coats of Watco Danish oil.

I am going to make several more for friends of mine for Christmas who do wood working.  I even made a mallet with a round head.

Thanks for reading please vote. I want a Instructables t-shirt in a bad way.


stuart.jones.75470316 (author)2015-08-13

great post. fantastic looking mallet!

nancyjohns (author)2014-05-12

It all started when somebody needed a mallet to pound pallets

clarkwerton (author)2013-10-30

That's really cool!

The Valiant (author)2013-02-26

Great looking Hammer! I have some oak pallets sitting in my garage just waiting for a project like this - Thanks for the idea.

djokimaki (author)2013-02-06

I bet that would look really slick if you turned it dowels and all! Nice work Ivan!

perryb (author)2013-01-10

The only thing I disagree with is how useful those dowels are. I just made my mallet, and once you see it "live" you'll see that without the dowels, if you strike something hard, there is a lot of force trying to knock off the two outer layers of the mallet head. But yep, those dowels sure do add a lot of "cool" to the project. If I figure out how, I'll post pictures of my attempt at this project. Thanks!

The Rambler (author)2012-12-28

Nice work. Those dowels are definitely a great touch.

Morte_Moya (author)2012-12-22

I work with aluminum all day at work. Skinning monument signs. This would help a lot! Thanks for the idea!!!

l8nite (author)2012-12-17

that's a good looking hammer, here's one I made several years ago in about 10 minutes, it gets left all over the place but it comes so in handy that I made 2 more this year using a broken fiberglass shovel handle for one and a scrap of closet pole for the other

yoyology (author)2012-12-15

If anyone ever asks, the answer to the question, "How many clamps do you need?" is always, "Just one more."

Tupulov (author)yoyology2012-12-17

AAAAAAHA-HA-HA-HA! How true. No matter how many I accumulate in my Cave I always seem to be just one short!

Tupulov (author)2012-12-17

Well done! This will be my project this coming weekend!

kz1 (author)2012-12-16

Very nice and simple. I think I might include the handle in the glue up, making sure to eliminate any play between handle and head bits. Great job on the one you built.

esemjay (author)2012-12-16

You know if you added "cringe" paint... you could make this look like thor's hammer. Kid's would love it...

shantinath1000 (author)2012-12-15

VERY nice!

pfred2 (author)2012-12-15

I gave up trying to win a Tee shirt. Nice mallet you made. I've made a beetle myself out of pallet wood. Mine isn't nearly as fancy as yours is. I suppose I should try to make a bit nicer one someday. I like making tools and hammers are definitely one kind of tool that anyone can make.

I've posted an article to this site about a hammer I made:

Next I want to make a hammer with a phenolic head. Here is a picture of my crude wooden hammer made out of pallet wood.

Nothing fancy but it gets the job done. I use it when I am gluing projects up, sometimes when I am chiseling.

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