Intro: 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.