Hello Ladies and Gents! Welcome to my shop! Today I will show you how to make a cool mallet fast We'll need a piece of wood about 45-15-2cm (18'-6'-3/4') my piece was a bit thicker so I'll plane it a bit We'll need a piece about 40-45mm (1.5-1.7') for the handle Now we need to mark the shoulder line on the handle It will be a tenon with two wedges I used the band saw for it but it can be done with a hand saw easily as long as the shoulders are even and 90 degrees any method is good Will layout two holes at the bottom of the cuts for the wedges The holes will prevent cracking of the handle now making two cuts for the wedges I like the shape of this Marples mallet only thing I'll tweak a bit is the size and the handle's shape and length marking the center and will make a three degree cut one such cut is all we need actually flip one part and we have a "mortise" for the handle it has the shape that will securely hold the handle will layout approximately how much we need to cut I added about 1-2 cm (0.5-3/4') to be safe for now I cut it at 90 degrees angle that will be the middle part of the mallet's head and this two pieces will be the outside parts of the mallet's head all cuts are only approximate Now you can see what I was driving at I saw some people make openings here and fill them with lead I don't need it as that white oak wood is heavy as is You have to glue this pieces fairly precisely you can put a little salt to prevent sliding I will just put a few tiny pins Turned out to be pretty snug at the "tenon's" handle you can also use this trick to prevent the wood sliding I used the spoke shave to shape the handle to fit my hand Feel nicely in my hand.
About 40mm here (1.5') As you can see the openings are different I will make 3 degree angle on the head just like on the Marples mallet the head will be just a little widet two 3 degree cuts and now will make the wedges I got about 5mm (0.2inch) on each side which means we need two wedges with about 5-7mm upper part so snug I need to hammer it in a little Now I will glue the wedges in mine are some walnut leftovers put some glue inside because if you put the glue on the wedge it most of it will be left out a little hammering don't use to much force for it I decided to make these tenons to further reinforce the glued head you don't have to do it, it is just my tendency to overbuild everything:) plus it will compliment the walnut wedges designwise will use tiny wedges here too:) the wedges go in perpendicular to the head's grain now this mallet is undistructable:) I rounded this part just like on the "model" So, the length is 36.5cm (14.5') Head's width is 12 to 13cm wide (4.7 to 5.1') 6.5cm (2.5') thick Looks pretty goo and feels good in my hand I like the handle and its weigh not much leftovers nice and hefty didn't dent much Thank you for watching! Happy Woodworking! Good-bye