This is a mallet I made for my daughter, she enjoys coming down to the shop with me and tinkering around. I figured I could practice some of my skills while also providing her with some tools of her own. Seeing as how a mallet is an essential tool in woodworking I figured I should start with that.
The head is made from some scrap oak and a piece of light-colored blockboard for a little contrast. All of the wood was either milled on my table saw or router table. Making mallets with a flat surface on top is important to me as I often set them down with the handle pointing up. This allows them to be ready to hand.
I chamfered all edges of the head to help prevent the wood from splintering and cracking. I also chamfered the edges of the handle to make it more comfortable to grip and less likely to cause splinters. The handle is secured to the head using oak wedges and wood glue.
I made the handle from a different supply of scrap oak and I think it may actually be red oak. Identifying types of wood is not something I am good at, so I could very well be mistaken. The grain in the handle isn’t as straight as I would typically like it to be, but I wanted to use what I had on hand. My daughter won’t be swinging this with all her might anyways, so I think it will serve just fine.
The handle shape is a little unique at the pommel because I did not continue two of the chamfers to the very end. I did this so that there would be somewhat of a “swell” to help it stay in her hand when she swings. She dearly wants something to whack with it, her brothers better be careful!
I finished it with boiled linseed oil and then added a few topcoats of a 50/50 clear Shellac and denatured alcohol mix. It isn’t the most durable topcoat, but it dries very quickly, which helps allow time for building it up with more coats. I haven’t made very many mallets in my time, but I consider this one to be my best mallet to date.
If you have any comments, advice, or requests for further details, please leave them in the comment section below. I read every comment!