-3/4" thick 6" wide by 18" long wood (I chose Maple)
-BB's, Lead weights, Dust from bench grinder, Steel bar stock, or any thing else that is dense and can fit in the mallet. (I went with BB's because you can buy a lot really easily)
-Wood glue (I went with titebond III because its my favorite)
-Leather (I bought mine at Michaels)
-Epoxy, craft glue, or super glue (what ever you want to glue leather with)
-Sand paper to use on palm sander at TechShop
-Wood Stain (what you want. Just there to keep the wood from staining from other sources)
I made this at TechShop
Step 1: Measuring and Cutting
Then take your wood and cut another section that is 10" long on the miter saw.
Step 2: Table Saw Time
Take your 6" long piece and cut them into 1-15/16" wide strips. this is for if your blade is 1/8" wide which it is for me at TechShop.
Then set your saw to 4-1/2" wide to make the handle 1-3/8" wide.
In the end you will have 4 pieces from this.
Step 3: Back to the Miter Saw
Step 4: Drill Press and Scroll Saw for Adding Weight
After the drilling i used the scroll saw to cut rectangles in the center. I made mine by guess the size. I would recommend this due to the weight you could be adding. You might need narrow and long or short and wide based off your weight.
Step 5: Glue, Clamp, Eat Popcorn, and Repeat
First take one of your edge strips that you cut and glue your two center pieces on the ends. Clamp and eat free TechShop Popcorn as your glue dries.
Then once glue has set add your weight and glue on the other edge strip. Clamp and repeat.
Step 6: Sand and Fit Your Handle
I sanded till it fit perfectly and installed with glue.
Step 7: Getting a Grip
Step 8: Drilling and Pinning
Step 9: Sand, Sand, and Sand Some More
Step 10: Staining and Finishing Faces
The last step is to attach leather to the face of the mallet. I did this with Tacky Glue. I have also been looking into putting leather on the handle but not sure about it.