Carve the flat parts for a laminated mallet, then glue and shape them into a shop tool. Explore full-size and miniature builds, or start by drawing a simple head and handle in Easel.
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Start from a blank workpiece
Start with a new blank workpiece in the real Easel editor. Make a 4 by 2 inch rectangle for the head, overlap a 1 inch-wide handle into it, then use Combine to join the shapes. Add two matching rectangles for the outer head cheeks. Set outside cuts to the half-inch stock thickness and inspect the three parts in the native 3D preview. This unsaved demonstration draws a simple 6 inch-long center layer with a straight handle. It shows the flat layout, not an assembled or test-cut mallet. The handle still needs shaping after glue-up; use a featured maker’s build for a more developed design.
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The miniature mallet fits in one hand. Full-size versions stack hardwood or plywood layers, with dowel pins on Christopher Young’s design to align the head.
A miniature mallet for small workby Thomas GonzalesThomas made his miniature mallet about 4½ inches long. Contrasting wood layers make the small head and handle easy to see in the finished photos. His shared layout supplies five pieces to carve and assemble. The gallery lists birch plywood, while the photos show contrasting wood; choose your own stock rather than assuming the preview describes every visible layer.
A laminated hardwood shop malletby Travis LuciaMake a traditional shop mallet from flat hardwood parts, then shape the handle after glue-up. Travis uses half-inch maple and cherry and adds carved initials to the head. His shared layout contains the center handle-and-head layers and the outer head pieces. Add your own lettering for initials like those in the photo. His instructions show cutting, gluing, shaping and finishing.
A plywood mallet with dowel pinsby Christopher YoungChristopher’s birch-plywood mallet has a square head and a straight handle. His finished photos show dowel pins through the laminated pieces. The shared layout includes the handle layers, head layers and matching holes; glue and dowels are separate supplies. Set the stock thickness to the plywood you use.
A personalized mallet for chisel workby Jeremy RichardsJeremy made this birch-plywood mallet to square pocket corners with a chisel. A carved letter makes the finished head easy to recognize in the shop. His shared design includes the handle, head layers and a paw-print decoration. Replace that decoration for lettering like the photo. Carve the flat parts, then glue, shape and finish them; the gallery does not provide a step-by-step assembly guide.
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Log in to post a question in the project comments. Replies are up to the community.
In the discussion on Travis’s mallet, Johnathan Branson suggests adding dowel holes to make glue-up alignment easier. It is a suggestion, not a reported test. Christopher Young’s separate plywood design already includes pin holes, and his finished photo shows the dowel ends. If you add pins to another layout, keep the holes in the same places on every matching layer.
Comment by Johnathan Branson: read the source.
From Woodworking Mallet by Travis Lucia.
Ask a questionChristopher says he used only two of the extra flat pieces in his layout and could use the other two for a wider head. That gives you a way to change the laminated head’s width without making the handle longer. Lay out the stack before gluing so you can check the width and the matching pin holes.
Project notes by Christopher Young: read the source.
From mallet by Christopher Young.
Ask a questionTravis spreads glue over the whole joining surface, then checks that the mallet’s faces stay even and flush as he tightens the clamps. A shifted layer leaves more wood to remove afterward. His optional bandsaw cleanup and handle sanding happen after glue-up, so leave that shaping for the assembled mallet.
Project notes by Travis Lucia: read the source.
From Woodworking Mallet by Travis Lucia.
Ask a questionKeep the center handle layer and outer head pieces aligned. Stack extra cheeks for a wider head, then shape the grip after the layers are glued.
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