The document provides instructions for making a wooden mallet. It details cutting out wood pieces with a scroll saw, rounding handles, gluing pieces together, drilling dowel pins for reinforcement, and finishing. Photos show each step of assembling the mallet.
The document provides instructions for making a wooden mallet. It details cutting out wood pieces with a scroll saw, rounding handles, gluing pieces together, drilling dowel pins for reinforcement, and finishing. Photos show each step of assembling the mallet.
The document provides instructions for making a wooden mallet. It details cutting out wood pieces with a scroll saw, rounding handles, gluing pieces together, drilling dowel pins for reinforcement, and finishing. Photos show each step of assembling the mallet.
The document provides instructions for making a wooden mallet. It details cutting out wood pieces with a scroll saw, rounding handles, gluing pieces together, drilling dowel pins for reinforcement, and finishing. Photos show each step of assembling the mallet.
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Note to commercial print employees: I give my permission to print as many of this pattern book as your customer requires.
steve@stevedgood.com
Copyright Steve Good 2014
Wooden Mallet
Get you wood and pattern ready.
Use blue painters tape on the wood then apply the pattern with sprat adhesive.
Take it to your scroll saw and cut all the pieces out. This hard maple was one inch thick so I used a #12 blade.
The oval hole in the center pieces is optional. If you wand a
heavier hammer you can cut this hole and ll it with lead shing tackle. Use an awl to mark the drill point for the 3/8 dowels. They will be drilled later after the pattern has come off.
Its time to round over the handle. Use a router or sand.
Notice where the round over ends.
Glue the center pieces to the back. We will use the
handle to get the placement right before the glue starts to set up. Make sure you get the top curves lined up correctly.
Test t the handle to get the center pieces lined up as
well as possible. We will sand everything ush later but get it as close as possible now. Now apply the glue for the handle.
Insert the handle and apply the glue for the other side of the mallet head. While the glue is still not dry take a moment to get everything as ush as possible.
Clamp it up and let it cure for a couple hours. Keep things
lined up while you put on the clamps.
To help secure the handle we are going to pin it with 3/8
dowels. Drill at the pre punched locations from the earlier step. Cut two dowels long enough to stick out on both side just a little.
Apply glue to the dowels and hammer them through the
mallet head. Sand every edge ush. Sand off the dowels ush. Sand a small 45 degree bevel on every edge of the head. I used an oil to nish the mallet.
Drill for 3/8 Dowels
after everything is glued up.
1 Thick
1 Thick
1 Thick
Optional
1 Thick
Optional
1 Thick
The holes are optional.
If you want a heavier hammer you can ll these full of lead shot.
