Introduction: Rubber Mallet Using Hot Glue

Picture of Rubber Mallet Using Hot Glue

Hi everyone! today i am going to show you how to make a rubber mallet. A rubber mallet is a hammer with rubber head used to deliver less impact than a steel hammer. We will be making one in our kitchen in less than a hour. Lets begin!!

UPDATE : Do comment , like and vote , I will select 3 random comments and send them a instructables patch. Who knows , this time you may be the winner of the patch. Winners will be declared in the comments. best luck!

Congratulations to 1)DTOM_Bear
2) gravityisweak

3) AngryRedhead

The randomly chosen winners of the DIY Patches.

Step 1: Gather the Materials

Picture of Gather the Materials

We will use following materials to make the head of the mallet.
1) 4-5 sticks of hot glue
2) A nonstick pan ---- or something to melt the glue sticks
3) Another pot full of water. -- Colder water is better
4) Cylendrical shaped empty Ice cream cup---- prefer the flat base one
5) scissors and basic tools

Step 2: Chop the Glue Sticks.

Picture of Chop the Glue Sticks.

Take the Ice cream cup and fill the chopped glue stick pieces into the cup. once the cup is full , add it to the pan for melting and cut another half cup of sticks because the air gaps between the sticks will give us false measurement. This way we are adding one+half cup of chopped sticks. The cup here is ice cream cup so the volume will vary from cup to cup according to size of the cup you chose.

Step 3: Melt the Glue and Add Colour

Picture of Melt the Glue and Add Colour

Heat the glue sticks till they melt completely and then add one - two spoons of colour which you like. I chose red. Add colour according to the volume of molten glue , in my case i added spoons approx. Steer it till it mixes well. Dont be worried of the bubbles arising after adding colour , they are due to the water in the ink and will cook away. I recommend the use of exhaust fan while melting because the fumes may be toxic and you dont want to breathe them in!

Step 4: Tilt the Pan to Gather the Glue on One Side.

Picture of Tilt the Pan to Gather the Glue on One Side.

Hot glue has tendency to solidify quickly so you dont want to waste time gathering the glue to a side after swithing off the stove. Tilting the pan while heating will help conserve time and will definately help to save glue.

Step 5: Pour It Into the Cup

Picture of Pour It Into the Cup

Carefully pour the glue into the cup we chose and not wasting much time, place the cup in cold water beaker. This will prevent the cup from deshaping due to heat.

IMPORTANT: The glue is extremely hot and if it gets on your body you may get severe burns. Be careful with what you are doing.

Step 6: Let It Solidify

Picture of Let It Solidify

Be patient , sit back and let the glue solidify.

Step 7: Break the Plastic Cup

Picture of Break the Plastic Cup

Rip off the plastic cup . The result is a rubber mallet head which now needs a handle.

Step 8: Install the Handle

Picture of Install the Handle

Just shape the head using a cutter and install the handle . For the handle first make the end a bit pointed using a chisel and then hammer it into the head. And.......... you are done.....

Step 9: You Are Done !!

Picture of You Are Done !!

We have just created a rubber mallet in no time. Thanks for reading this instructable , if you like this perhaps you like some of my others. check them out ! Merry Christmas.

Comments and suggestions are appreciated. Do like and vote for this i'ble. Thanks again.


DTOM_Bear (author)2014-12-29

Interesting. I agree with "gravityisweak" that molding the handle into the head would be stronger (file grooves into the handle to give the plastic something to flow around for a stronger bond). Another option might be to bore a hole all the way through the head, insert the handle, then drive a wedge into the head-end of the handle (look at a commercial hammer to see what I mean).

I also wonder about the durability of the head itself. What sort of projects do you use this for? I do some light metal work, and suspect the head would wear quickly. You might try "coloring" with fine carbon powder (finely ground charcoal, like you'd use to make india ink). Carbon is used in rubber to improve durability; it might work with this plastic.

Congratulations to 1)DTOM_Bear

2) gravityisweak

3) AngryRedhead

The randomly chosen winners of the DIY Patches.

gravityisweak (author)DTOM_Bear2014-12-29

That is a good idea too. Taking it another step further, what about laying down a piece of harder rubber on the bottom of the mold before you pour? That way the final mallet would have a more durable rubber making contact with whatever you are hitting.

A good idea. Could it not be accomplished after the casting process by gluing a suitably shaped hard rubber piece to the strike face of the new mallet head? If you have access to hard rubber- why not make the entire mallet head out of it? If you live in N.America you have ready access to suitable rubber of high quality and low price: Hockey pucks! Don't glue them together to form the mallet head, bolt them together with washers and lock nuts-ensuring the bolt is properly sized to permit both ends of the bolt to be recessed into, and not interfere with, the strike face. I wouldn't suggest melting real rubber in an attempt to cast it. I predict it would decompose or "de-vulcanize" rather than liquify into any substance that could be reused and cast into the form of a mallet head.

There you go! You have the beginnings of your own instructable right there!

Yonatan24 (author)2016-04-12

I made my own Hot-Glue Mallet, And Instructable!

Your method didn't work very well for me, But I used a different method. I credited you and gave a link to your Instructable in my Instructable, Thanks for the inspiration!

Yonatan24 made it! (author)Yonatan242016-04-12

Here are some pictures

ArticAkita (author)2015-11-17

very clever idea, I should give it a try! have a good day!

chrisjlionel (author)2015-07-15

Adding sulphur with hot glue will give good strength to the mallet.

vaggelas made it! (author)2015-05-26

Very good idea.Congrats.

A "copy" that i made with the handle molded on. 3 things i noticed.

1. It works great. You can bang it with all your force and it will still be ok

2. Hot glue is flammable if overheated and has a lot of fumes, so wear mask and use low temperature.

3. Hot glue is impossible to work with if gets solid. You can't saw it, drill it, sand it or do any work that produces heat, it will melt and stick on your tools (tried to trim it with a hand saw and destroyed the blade in few seconds). You can use only a knife.

ZareerW (author)2015-02-03

hey that was nice, but will it last, what I mean is it tough enough.

Thanks as I was thinking about it.

realmccormick (author)2015-01-23

Those that are concerned about the head flying off could always use some E6000 glue, let sit 24 hours and it's just not coming off. Also, to those who say that this head is too soft, "You all must not do any jewelry work with silver and other metals". This would be perfect for that application, to be used in conjunction with some smaller heads. In jewelry making, all sorts of hammers are used, and to purchase them is monetarily prohibitive for most jewelry hobbyists! Good Going for this creative idea!

firefightermeyer (author)2015-01-09


firefightermeyer (author)2015-01-09


firefightermeyer (author)2015-01-09


Chitlange Sahas (author)2015-01-06

Congratulations to 1)DTOM_Bear

2) gravityisweak

3) AngryRedhead

The randomly chosen winners of the DIY Patches.

Chitlange Sahas (author)2015-01-06

Congratulations to 1)DTOM_Bear

2) gravityisweak

3) AngryRedhead

The randomly chosen winners of the DIY Patches.

abeimers (author)2015-01-01

Nice I did it too i need a mallet so I used your way

JaredDiS (author)2014-12-31

Well this project is good and all, but the handle has to be secured to improve the safety of using this tool. Possibly drilling a hole through the side of the mallet and the handle and place a metal rod of some sort and secure it with glue. That way no matter how fast you swing the mallet, it will stay firmly attached and will not come flying off and injure or even possibly kill someone that is near you.

script_coded (author)2014-12-30

This could be used for molding too!

dorchard (author)2014-12-29

Very interesting. I too worry about durability, both of the handle joint and the rubber itself. But it should be cheap enough to make a quick mallet for small jobs.

It'd be perfect for committing insecticide.

andrew.mead.1253 (author)2014-12-30

Your hot glue idea is admirable and I tip my hat to you. In the form depicted the mallet is too light in weight to be useful for general purpose work. I suggest the head be cast larger and lead shot be added to the molten glue. Additionally, I propose drilling a 1/2" dia. shaft through the side of the head (and inserted wood handle) to allow a 1/2' dowel or steel pin of suitable length to fasten the handle to the head. Otherwise, the head will not likely remain attached to the handle after enduring a number of blows. Btw--the addition of lead shot would not transform the mallet into a dead-blow hammer--unless the lead shot was contained by a cavity within the head roughly twice the area required to minimally encapsulate the lead shot. I already own a number of mallets and dead blow hammers, so I'm not about to make another--that's up to you in the event you're inspired to engage the suggestion(s). Thanks for reading.

jdunk67 (author)2014-12-30

I would have cut a slit in the side of the cup to stick the handle through, then poured the glue over. And why not just use the hot glue gun to put the glue into the cup? Then you wouldn't have had to clean up a pan

andytangtsk (author)2014-12-29

Maybe it would be more uniform if you cast it in a pipe? And did you use that pan for cooking again? :)

Pan cant be used to cook but can be used for other projects.

AngryRedhead (author)2014-12-29

How did the pan do after all the melting? Were you able to get all the glue out?

I used the non stick pan. it came out easily after drying. You just need to peel out the glue once it cools.

Ismegordo (author)2014-12-29

What a great idea and you can tell how good it is by the comments mad, everyone loves it and have looked at different ways to improve it. But the original idea was yours.
I do agree with the moulding of the handle into head at the time of pouring is a great idea and one that is easy to try, while also adding either PVC glue or something similar to help hold the mixture together better. Anyway I have voted, Good luck and keep them coming.

em loves crafting (author)2014-12-29


Wefneck (author)2014-12-29

Have you tested the durability of the final product? I am thinking of making one to use for some of my wood work but I'm concerned I wouldn't be able to use the force I need with this tool. How has it held up?

computer freak3 (author)2014-12-29

that's way kool I agree about molding the handle on it could also use a PVC ring in the cup before you pour it,it would help hold the head together and to make to really personnel you could do the glue in stages and color each section different

jcalario (author)2014-12-29

Nice instructable.

michaelrobbutler (author)2014-12-29

Good idea, i agree with molding the handle on, really good idea and something we can all try and improve on

gravityisweak (author)2014-12-29

I love the idea! But I don't think that handle is very secure. The head of the mallet could fly off. Instead of banging the handle into the formed mallet, I think the handle should be poked through the ice cream cup before the glue is poured. This way the glue can bond to the handle. I'll have to give this a try!

Knextremely stupid (author)2014-12-29


Knextremely stupid (author)2014-12-29


Liam1909 (author)2014-12-29

So cool and so easy just voted

Purple_Matter (author)2014-12-29

This is such an awesome idea!

Thank you so much . Do vote for me.

About This Instructable




More by Chitlange Sahas:The Spyder-Pod - Your DSLR's New Friend!"With U Smart Sole" DIY GPS Embedded Smart Shoe sole #MITBetterWorld DIY Personal Metal Key-chains
Add instructable to: