Rebuilding a Shop Mallet

Article 165: Rebuilding a Shop Mallet

By: A Woodworker Who Uses a Mallet Like a Chisel's Best Friend

A wooden mallet takes years of punishment. When the head splits or the handle loosens, it’s time for a rebuild. You can often reuse the handle and just replace the head.

Materials

• Mallet head block: 3" × 4" × 6" (ash, hickory, or maple)

• Handle: reuse or shape from hardwood (1¼" thick tapering to ¾")

Tools Required

• Saw

• Rasp or spokeshave

• Chisels

• Drill (for wedge slot)

Instructions

1. Shape the Handle

   • Oval cross-section preferred.

   • Leave a shoulder to seat in the head.

2. Mortise the Head

   • Chop or drill a tapered hole through-center.

3. Dry Fit

   • Fit handle snug, should sit slightly proud.

4. Wedge and Glue

   • Saw kerf in top of handle, insert wedge with glue.

   • Drive into mallet head.

5. Finish

   • Sand and apply tung oil or BLO.

Sketch – Mallet Head Fit

   _______
  |       |
  | HEAD  | ← Hardwood block
  |_______|
     ||
   HANDLE (tapered, wedged at top)