Make A Wooden Mallet

This handy wooden mallet was made from some left-over scraps of oak that I had salvaged from a pallet.

The mallet is five pieces of 3/4" thick hardwood.

1 only "Handle" - 3/4" X 1" X 10 1/2"

2 ea. "Short Head Sections" - 3/4" X 2 1/4" X 1 1/4"

2 ea. "Long Head Sections" - 3/4" X 2 1/4" X 3 1/2"

Make sure the "Handle" and the "Short Head Sections" are exactly the same thickness.

Glue the two "Short Head Sections" to the handle, making sure the surfaces are lined up.
When the first glue-up is dry, glue the "Long Head Sections" to each side. Using three clamps as shown with waxed paper between the head parts and the scrap wood will keep the parts from creeping.

After the glue has set drill a 3/8" hole for a dowel throught the midpoint of the head, crimp the dowel with a pair of pliers, apply glue and drive it in.

Sand all surfaces of the head smooth, then round all sharp corners on the head and handle with sand paper.