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Travis Lucia

Project by

Travis Lucia

General Information

A traditional style woodworking mallet is a great addition to any shop! This project allows you to quickly carve and customize your own personal woodworking mallet.

Like this project Open in Easel®
Material Description Price
Cherry Wood

Cherry Wood (×2)

6" × 12" × 1/2" Cherry Wood

$13.98

Hard Maple

Hard Maple (×2)

6" × 12" × 1/2" Hard Maple

$10.98

$24.96
from Inventables

File Description Unit Price
File-type-blank

Mallet.svg

$0

Download Zip

$0
from Inventables

1

Materials and Tools

1 minute

Materials:

-1/2" Hardwood (I used hard maple and cherry, both are available from inventables)

-Wood glue (Tightbond 2 is my preference)

-Finish (Finish is optional but will greatly enhance the look of your finished product, I used spray on polyurethane)

Tools:

X-carve
Bandsaw (Optional)
Random Orbit Sander

2

Open the Project in Easel

5 minutes

Open the project in easel and customize it to your liking with your initials or a simple design!

Set up your material and secure it tightly to the wasteboard.

3

Carve!

60 minutes

I used an 1/8" 2 flute straight bit from bosch.

4

Layout

2 minutes

Layout your pieces, clamps and get your glue ready. It helps to have a silicone glue brush for spreading the glue around the pieces evenly but this can be achieved using your finger or a paint brush.

5

Glue

5 minutes

Add glue to the faces that will be joined together spreading it out to ensure total coverage of all surfaces.

6

Clamp

3 minutes

Quickly add clamps to your glued mallet, the more clamps the better! Check the surfaces when tightening clamps to ensure things are staying even and flush.

7

Bandsaw (optional)

5 minutes

If you have a bandsaw and your pieces shifted slightly the bandsaw can be an excellent option for cleaning up and making faces perfectly even.

8

Shaping and Sanding

15 minutes

Shaping the handle, smoothing edges and faces as well as adding a customized feel can all be accomplished using a random orbit sander a clamp and a low grit sanding paper.

9

Finishing

Finish is an optional step but will greatly enhance the look of your finished product as well as add life to the tool. I used 3 coats of a simple and quick spray on polyurethane sanding between coats with 320 grit sandpaper.