Why make a wood mallet? There are a lot of reasons for needing a wood mallet, this one was designed to be used as a Metal Shaping Mallet, but you could use the following process to make pretty much any kind of mallet you would like. I wanted to try my hand at making gas tanks and fenders for Motorcycles, and did not want to drop around $80 to buy a plastic set.
An Oak board (available at any lumber or home improvement store) I got mine at Loews from probably around $15 give or take.
Wood Glue (also available many places including the home improvement store) lucky there was some available for my project at Tech Shop.
I also utilized the scrap wood bin at Tech Shop to find a bit of wood suitable to make the handle.
Step 1: Step 1:
Step 2: Step 2:
A. Avoid getting glue on the out-er edges of the wood, but make sure to completely cover the faces you are joining
B. Align your pieces so the grains go against each other (in my case you could see a slight U or Rainbow shape... so I glued them so the ends of the rainbow touched each other, if that helps you visualize what I am talking about).
C. Bar Clamps are better for this application than C Clams as they will apply more pressure and more evenly.
Once this is complete it is time to wait for the glue to dry giving it a good 24 hours. since will will be chucking this up in a lather and spinning it at upto 1200 RPM we want to make sure there is a good solid bond.
Step 3: Step 3: Clean the Edges, Find Center, and Chuck It Up
make sure there is a nice even surface on both sides of the block.
We then want to take a pencil and draw a strait line from corner to corner crossing the center of the block (on its ends) to find the center of the piece.
Then we take our block to the ban saw and take off the corners of the block. Making our block into more of an octagon shape will help make the work on the lathe go much faster and easier.
X marks the spot, where we want to set the chucks on the wood lathe. This will help us not waste material getting the work piece centered and round.
Step 4: Step 4: Wood Lathe
I wanted to get a "pear" shape mallet with about a 3" head on one side and a smaller surface on the opposite side. Its a pretty easy process working on the wood lathe and practice certainly helps. I just eyeballed this and got a pretty good result the first time.
After I got the shape I was after, I applied sand paper (220 grit , then 300 grit, then 400 grit) while it was still chucked up. I did however reverse the direction of the lathes rotation as it made it more comfortable to sand. at the end I used some of the shavings packed into a puck in my palm to burnish the mallet head giving it a nice glossy finish
Step 5: Step 5: Un Chucked
We then set up the mallet head in the drill press to drill out a hole through the center... where we could glue and tap in a wooden handle (also made on the lather using the same steps as previously outlined).
Step 6: Step 6: the Test
Hope you found this informitive and useful.