How to Make a Plywood Mallet

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About: My name is Suso Caamanho. I like doing all sorts of stuff related to musical instruments, woodworking, computer science, electronics... On my website you will find more information, projects, plans, photos...

Intro: How to Make a Plywood Mallet

I'm going to make a mallet. Let's take a look at how to make it. First we glue the printable template onto the plywood board. You'll find in this link where you can download it for free.

Video for mobile devices.

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.

2 People Made This Project!

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11 Discussions

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JAC_1961weaverbrosracing

Reply 2 months ago

The one I made is holding up fine. It's not like you'd be driving nails with it. It's a mallet, meant to tap stuff not beat it into submission. ; )

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deluges

2 years ago

Nice project! Easy diy tool making, always useful.

I think I remember seeing a similar project on here recently but the mallet was a deadblow... Maybe it wasn't on instructables cause I can't find it.

To make it deadblow, you could route or scrollsaw a cavity inside the middle (handle) piece and fill the hole with about 75% in volume of steel balls, that'd make it significantly less bouncy :)

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mach1950

2 years ago

Nice 'able again sir. And a lovely mallet. I will make my next one.

1 reply