Turning a Wooden Mallet on the Lathe

Article 113: Turning a Wooden Mallet on the Lathe

By: A Woodworker Who Prefers His Tools Handmade

A lathe-turned mallet is perfect for chisel work and can be tailored for balance and feel. We'll use maple for durability and ash for grip.

Materials

• 3" × 3" × 5" maple blank (head)

• 1.5" × 1.5" × 12" ash blank (handle)

• Wood glue

Tools Needed

• Lathe and turning tools

• Calipers

• Drill and Forstner bit (7/8" or 1")

• Mallet and clamps

• Sandpaper and oil finish

Steps

1. Drill Head

   • Bore hole in center of mallet head blank (lengthwise).

2. Turn Handle

   • Shape to taper gently, fit snugly into mallet head hole.

3. Glue and Assemble

   • Insert handle, glue, and clamp if needed.

4. Shape Head

   • Mount entire assembly on lathe; round ends and balance.

5. Finish

   • Sand to 320 grit and apply linseed or tung oil.

Visual – Mallet

Side View:
   _______
  /       \ ← Mallet head
 |         |
  \_______/
     ||
     ||
     || ← Handle taper