How to Make a Plywood Mallet

I'm going to make a mallet. Let's take a look at how to make it. First we glue the printable template onto the plywood board. You'll find in this link where you can download it for free.

Video for mobile devices.

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 birchthe 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 together 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.