How to make a Plywood Mallet

How to make a Plywood Mallet


Today I’m going to make a mallet. As you can see this is the Sketchup file you’ll find in the plans along with the printable template You’ll find a link in the video description
where you can download it for free. Let’s take a look at how to make it. First we glue the printable template onto
the plywood board Using an inverted jigsaw, we cut along the
lines 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 sturdy, so it can last for a long time! Now we’ll sand the edges on the belt sander We’ll reuse the leftover plywood to trace
and cut the other two parts of the 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 We’ll do the final steps by hand. Apply rasps and sandpaper to the handle, making it more comfortable to the touch Now that that’s done, it’s time to assemble the three pieces togheter with wood glue Once they’re dry, we’ll sand the piece on
the sanding drums with the help of a follower, which will even out any length differences
between the pieces We’ll also take the chance to smooth out the edges We’ll use sandpaper for the final touch, and then it’s time to apply some varnish. And it’s done! we hoped you liked it and see you next time

3 thoughts on “How to make a Plywood Mallet

  1. If you'd like to help me, you can upload subtitles in your own language following this link:
    http://www.youtube.com/timedtext_video?ref=share&v=I4Kis3jDP3k
    Puedes contribuir con subtítulos en tu idioma en el siguiente enlace:

  2. many thanks
    i have just downloaded plan for this mallet via your web and started with my first mallet but here it is out of regular plywood rather than birch, it was done with hand held jigsaw because am still lacking the correct means for good start. anyway if this plywood won't last long it will still be a good practice for next projects. ad for your web, it certainly has lot of potential in helping me with my start up!

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