Introduction: How to Make a Plywood Mallet
Step 1: Cutting Along the Lines
Using an inverted jigsaw, we cut along the lines.
I've tried to stick a simple design so that it's easy and affordable to make. Besides, this type of birchthe board is quite sturdy, so it can last for a long time!
Step 2: Sanding the Edges
Now we'll sand the edges on the belt sander. We'll reuse the leftover plywood to trace and cut the other two parts of the mallet.
Step 3: Rounding for Better Handle
Using a roundover router bit we'll round out these parts of the handle, and with the help of a router bit with a wider radius, we'll round out the mallet grip.
Step 4: Improve the Handle
We'll do the final steps by hand. Apply rasps and sandpaper to the handle, making it more comfortable to the touch.
Step 5: Glue the Three Pieces
Now that that's done, it's time to assemble the three pieces together with wood glue.
Step 6: Sanding the Differences Between the Pieces
Once they're dry, we'll sand the piece on the sanding drums with the help of a follower, which will even out any length differences between the pieces.
Step 7: Smooth Out the Edges
We'll also take the chance to smooth out the edges.
Step 8: Final Touch
We'll use sandpaper for the final touch, and then it's time to apply some varnish. And it's done!, we hoped you liked it.
Participated in the
Wood Contest 2016