I used different woods here than the handle. But you can hold all together the same. Also I went with .75 thick stock. The original mallet was 1/2 glued together.
First glue only one face side to the handle part. This is important because you need to fill the open cavity with something. As seen in the video I also used metal. I poured in resin to stabilize the head.
Once you have the head glued and filled with weight, then assemble the other face on.
I have included a G-Code file for the face carve. It is set up for a 90 degree v bit on an x-carve.
I recommend you try it on a sample piece before you carve your mallet head.
The cut needs to be centered on the mallet. Mark the center by drawing a line from corner to corner making an “x” on the head. I used a wooden clamp to hold it on my x-carve.
The cut will go off the edges of your mallet. this is to cover the total head with the pattern. Make sure your mallet is both centered and parallel with your x-carve. Mallet handle towards the back of the x-carve and the head facing the front.
A test cut will show you the alignment.
The cut should take 3 mins per side.
That’s it, Good luck, I want to thank Jeremy for his design and video.