Picture of Wooden Mallet Made. I made it at TechShop
Shopping list:
-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

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Step 1: Measuring and cutting

Picture of Measuring and cutting
Take your piece of wood and cut on the miter saw at 6" long. 
Then take your wood and cut another section that is 10" long on the miter saw. 

Step 2: Table saw time

Picture of Table saw time
Take your piece from the miter saw and go to the table saw.
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

Picture of Back to the miter saw
The next step is to mark one of the smaller strips for inserting the handle. I make mine 1-1/4" wide so i could sand down the handle to make it fit perfectly. I put mine in the center so i could have a balanced mallet. 

Step 4: Drill press and scroll saw for adding weight

Picture of Drill press and scroll saw for adding weight
The next step is to use the drill press on the two pieces you just made on the miter saw to put holes in the center of them. I used a 3/8" drill bit for this. 
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. 
billyork2 years ago
red oak
billyork2 years ago
red oak
I dont think that's maple, I think it's an oak of some kind.
ortho2 years ago
That looks like oak