This project saves money and also might be useful if there aren't any retail stores close to you.
Make sure to check out the DIY Air Hockey Table instructable!
If you've got any remarks or anything else to say, don't hesitate to comment.
Step 1: Requirements
I've tried to make making mallets as easy as possible, with the most common materials. You probably have these materials lying around:
A piece of plywood which is at least 13cm x 13 cm and is about 2 cm thick.
A PVC tube with an outer diameter of about 4 cm and a length of about 7 to 8 cm. You can consider the option of using the end of a broomstick, if it has the right diameter. This handle can be a little shorter.
Scratch preventive material
An old piece of circular sandpaper (those with soft backs). You can also use a piece of felt.
-Drill and Hole saw (with an outer diameter of 9.5 and 4 cm)
-File and some sandpaper
-Close contact glue
Step 2: Making Plywood Ring
A: Saw a straight hole through the plywood using the 9.5 cm (3.7 inch) hole saw.
B: Then saw a hole through the middle of this disc using the 4 cm (1.5 inch). Ensure that you have a slightly smaller hole than the PVC tube's diameter (not too big).
Step 3: Attaching PVC Handle
C: File the hole in the plywood disc until the PVC tube fits snugly. Push the tube through to the end of the hole. We're not using any glue to keep the handle in place, so make sure the handle can't slip out in any way.
D: Saw the tube to an appropriate length.
E: File all edges of the PVC and plywood to get rid of burrs.
Step 4: Attaching Scratch Preventive Material
You don't want to get scratches all over your playing surface. Here is what you need to do:
F: Glue the 'rough' side of the sand paper and the bottom of the plywood ring. Leave both the sandpaper and the plywood to dry for a minute before putting them together.
G: Now cut away the sandpaper that sticks out.