Make a Mallet (or Two) Woodworking Plan
The best mallet you'll ever use may be as close as your scrap bin. You need only two pieces of hardwoodäóîwe used maple for the head and hickory for the handle. The handle locks into a wedge-shaped mortise for a fit that tightens with use. Build the smaller mallet for light assembly work and for use with 1"-and-narrower chisels. The larger version gives you more striking power with big chisels and provides greater "persuasion" with tight-fitting furniture and cabinetry joints. You can, of course, make an even smaller mallet for fine, delicate work, or bigger for framed structures.
WOOD Issue 250, November 2017