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Are you a woodworker? Do you have a woodworking hammer then?

If the answer was yes to both then you are good to go but if it was no to just one, then this instructable is just right for you!

Let me show you how to make a proper woodworking mallet for cheap and just in one hour! ( It took me 5 hours as I was making 3 of them while photographing, videotaping and drinking beer :D) But you might ask "why do I need one, why not just use a regular metal hammer?" Well, the answer is simple - wood is soft and if you pound it with any material stronger than itself it leaves dents and believe me, nothing is worse than hammer marks on your woodworking project! That's why I like to make my own woodworking mallets from materials readily available in my scrap bin and hardware store. And in fact, I like to keep several mallets with me at all times when working since I tend to lose them a lot. This is why I designed this super simple, yet super reliable woodworking mallet design that will not let you down!

A few years ago I posted another mallet design that was made from firewood. It was great in theory but practically not so much since the wood I used could not take the pounding and the handles just broke. You can see the post here!

Do you think you have an easier woodworking mallet design? I would love to see your design in the comments!

But enough talk, let's get started!

Step 1: What You Will Need

Picture of What You Will Need
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The materials list for this build is pretty short!

  • Square material. This can be a premade stud like you see in the picture (100x100mm) or you can glue many smaller pieces together to create the same thing. All the wood I am using is pine ( Pinus sylvestris) as this is the cheapest and most available type of wood here. A bonus is also that it is softwood. It might also make dents in your workpiece when you are using hardwood for the mallet.
  • Round pole. This I had to actually buy since I wanted it to be comfortable in hand. In the hardware store, I tried holding different sized wooden poles and felt which one would feel the most comfortable. I ended up with one that was around 28 mm in diameter
  • Optionally you could also add Cork board on each end of the hammer. This will soften the blow and further ensure dentless workpiece.
  • Wood glue and linseed oil

As always I like to say that the best tool is the one you have, so be creative! You do not need to have all the tools that are named down below!

  • Table saw and/or hand saw
  • Drill press/cordless drill with a spade bit (similar diameter as round pole)
  • Disc sander and/or regular sandpaper
  • Two clamps and two scrap boards for glueing the cork boards
Nice quick project. Sub'd on YouTube!
Sethsg2 months ago
Very clear ible also nice photos well done.
CraftAndu (author)  Sethsg2 months ago
Thanks!
wes_van2 months ago
Nice project, I love how simple this is to make with many possibilities to 'customize'.
You got my vote.
CraftAndu (author)  wes_van2 months ago
Thanks! I really appreciate it!