Today I’m going to make a mallet. I’ve tried to stick a simple design so that it’s easy and affordable to make. Besides, this type of birch board is quite sturdyand heavy, so it can last for a long time!

Homemade-plywood-mallet-plans

As you can see in the video, this is the SketchUp file you’ll find in the plans along with the printable template. You’ll find in my shop for free:

Plywood Mallet Plans

 

Homemade-plywood-mallet-printable-template

Let’s take a look at how to make it. First we glue the printable template onto the plywood board.

Homemade-plywood-mallet-making

Using an inverted jigsaw, we cut along the lines.

How-to-sand-woodworking-plywood-mallet

Now we’ll sand the edges on the belt sander.

How-to-cut-woodworking-plywood-mallet

We’ll reuse the leftover plywood to trace and cut the other two parts of the mallet.

How-to-mill-woodworking-plywood-mallet

Using a roundover router bit we’ll round out these parts of the handle, and with the help of a router bit with a wider radius, we’ll round out the mallet grip.

 

How-to-file-woodworking-plywood-mallet

We’ll do the final steps by hand. Apply rasps and sandpaper to  the handle, making it more comfortable to the touch.

How-to-glue-woodworking-plywood-mallet

Now that that’s done, it’s time to assemble the three pieces togheter with wood glue.

How-to-sand-woodworking-plywood-mallet-drum

Once they’re dry, we’ll sand the piece on the sanding drum with the help of a follower, which will even out any length differences between the pieces.

How-to-router-mill-woodworking-plywood-mallet

We’ll also take the chance to smooth out the edges.

How-to-sand-wood-plywood-mallet

We’ll use sandpaper for the final touch…

How-to-varnish-woodworking-plywood-mallet

…and then it’s time to apply some spray varnish. And it’s done!

 

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