-3/4" thick 6" wide by 18" long wood (I chose Maple)
-BB's, Lead weights, Dust from bench grinder, Steel bar stock, or any thing else that is dense and can fit in the mallet. (I went with BB's because you can buy a lot really easily)
-Wood glue (I went with titebond III because its my favorite)
-Leather (I bought mine at Michaels)
-Epoxy, craft glue, or super glue (what ever you want to glue leather with)
-Sand paper to use on palm sander at TechShop
-Wood Stain (what you want. Just there to keep the wood from staining from other sources)
I made this at TechShop
Step 1: Measuring and Cutting
Take your piece of wood and cut on the miter saw at 6" long.
Then take your wood and cut another section that is 10" long on the miter saw.
Step 2: Table Saw Time
Take your piece from the miter saw and go to the table saw.
Take your 6" long piece and cut them into 1-15/16" wide strips. this is for if your blade is 1/8" wide which it is for me at TechShop.
Then set your saw to 4-1/2" wide to make the handle 1-3/8" wide.
In the end you will have 4 pieces from this.
Step 3: Back to the Miter Saw
The next step is to mark one of the smaller strips for inserting the handle. I make mine 1-1/4" wide so i could sand down the handle to make it fit perfectly. I put mine in the center so i could have a balanced mallet.
Step 4: Drill Press and Scroll Saw for Adding Weight
The next step is to use the drill press on the two pieces you just made on the miter saw to put holes in the center of them. I used a 3/8" drill bit for this.
After the drilling i used the scroll saw to cut rectangles in the center. I made mine by guess the size. I would recommend this due to the weight you could be adding. You might need narrow and long or short and wide based off your weight.
Step 5: Glue, Clamp, Eat Popcorn, and Repeat
Then come the fun part of watching glue dry.
First take one of your edge strips that you cut and glue your two center pieces on the ends. Clamp and eat free TechShop Popcorn as your glue dries.
Then once glue has set add your weight and glue on the other edge strip. Clamp and repeat.
Step 6: Sand and Fit Your Handle
To add the handle i marked how for in it would go all the way around the handle then i sanded the two sides that didnt fit to fit in perfectly. If you are like me and cant glue straight then make sure you are inserting the handle from the largest side to make a taper fit. Be careful not to grab another mallet to make it fit. This could result in breaking the glue joints.
I sanded till it fit perfectly and installed with glue.
Step 7: Getting a Grip
Next i took my glued handle and started to shape it on the disc sander to round the edges. This for me to make sure i did it right and got it to the right size. Then i finished it up with the palm sander later.
Step 8: Drilling and Pinning
The next step i took was to pin and dowel two holes to ensure i secured the handle and to make it look a little cooler. I made my holes 3/8" from the top and 3/8" from the edge of the handle. My second hole was 3/8" from the bottom and 3/8" from the other side of the handle. I drilled my hole 3/8" then cut 2 3/8" dowel pins from dowel rod. I made my pins a lot longer than i needed so it was easier to work with. Then insert the pins with glue and watch it dry.
Step 9: Sand, Sand, and Sand Some More
The next step is to sand the pins down and ever face of the mallet with the belt sander and palm sander. I also sanded down the handle at this point.
Step 10: Staining and Finishing Faces
Staining the mallet is the next step. I went with something i had laying around. I plan on making this mallet a little dirty so i just want to make sure that i stain it well enough that i dont make it a lot worse later.
The last step is to attach leather to the face of the mallet. I did this with Tacky Glue. I have also been looking into putting leather on the handle but not sure about it.