How to Make a Wood Mallet

The Making of a Wood Jointers Mallet

Making a wood mallet is a quick an easy woodworking project anyone can do with some basic woodworking tools. For this project I decided to use some fancy leftover coconut palm wood but any wood will do. I begin by cutting the hammer head to 5.5″ long, 2″ tall out of 1.5″ thick stock. I then drill a 1″ hole completely through the top as this will hold the handle tenon. The handle is cut to 11.5″ in length and turned on the lathe. The tenon should fit easily into the hammer head mortise and then split down the middle on the bandsaw. This will allow me to make a wedge that will hold everything together very snug with wood glue.

For aesthetic reasons I wrapped the handle with baseball bat tape and tapered off the ends of the hammer head. And just for fun I laser engraved MC Hammer on one side and the phrase “Please Hammer” on the other referencing the hit album “Please Hammer Don’t Hurt ‘Em.”