Pallet Mallet
Intro: Pallet Mallet
I needed a wood mallet and kept forgetting to grab one at the store, so I made one. My buddy casey gave me some red oak pallets and they had been sitting in my woodshop (garage) for several months now. I figured I would try to make one from that wood.
STEP 1: Preparing the Wood
Remove any nails and thickness plane the boards. The board started at 1" thick by the time I was done the final thickness was 3/4 of an inch.
STEP 2: Lay Out
I took the wood to my chop saw and started cutting. No real plan here just cut the boards how I thought they should be cut.The head of the mallet will be three boards wide. The outside boards will be one peace 9 inches long. the the center boards will be cut in two each 3.5 inches leaving a gap for the handle.
STEP 3: Glue Up
I glued the boards together and left a 1.75 inch opening in the middle of the block for the handle. So this is the time if you are a friend or family member or a clamp supplier to realize a good Christmas gift this year is wood clamps. I made it work with what I had. After the glue set up I drilled some 3/8 holes for some walnut dowels. I do not think they are necessary it just looks cool. i then cut a 5 deg bevel to the head of the mallet. this also squared up the mallet face.
STEP 4:
The handle I ripped a peace of the same pallet wood 1.5 inches wide for the handle. I then when went over to my Shopsmith and started turning the handle. I wanted the handle to stick out of the top of the hammer because it looks cool. So I just started turning. I finish sanded the handle to 600 grit.
STEP 5: Finishing
I inserted the handle in to the head of the mallet and drove two more dowels in to the mallet head to secure the handle. After this I hand sanded the dowels and passed the complete mallet through the planer to trim the dowels perfectly smooth. I did about 5 min of hand sanding to 600 grit. I finished the handle with three coats of Watco Danish oil.
I am going to make several more for friends of mine for Christmas who do wood working. I even made a mallet with a round head.
Thanks for reading please vote. I want a Instructables t-shirt in a bad way.
I am going to make several more for friends of mine for Christmas who do wood working. I even made a mallet with a round head.
Thanks for reading please vote. I want a Instructables t-shirt in a bad way.
16 Comments
stuart.jones.75470316 8 years ago
great post. fantastic looking mallet!
nancyjohns 10 years ago
It all started when somebody needed a mallet to pound pallets
clarkwerton 10 years ago
The Valiant 11 years ago
djokimaki 11 years ago
perryb 11 years ago
The Rambler 11 years ago
Morte_Moya 11 years ago
l8nite 11 years ago
yoyology 11 years ago
Tupulov 11 years ago
Tupulov 11 years ago
kz1 11 years ago
esemjay 11 years ago
shantinath1000 11 years ago
pfred2 11 years ago
I've posted an article to this site about a hammer I made:
https://www.instructables.com/id/Brass-Hammer-Build/
Next I want to make a hammer with a phenolic head. Here is a picture of my crude wooden hammer made out of pallet wood.
http://i.imgur.com/oTCjy.jpg
Nothing fancy but it gets the job done. I use it when I am gluing projects up, sometimes when I am chiseling.