Make a wood mallet. A must-have for any woodworker.

six years ago I made this Thor's hammer well of course I didn't know it was Thor's hammer back then but it's a good woodworking mallet and since then I've made about four of these it's all made of hardwoods and the top is held together with this tenoning and wedge system and I put leather on each side to cushion blows I picked up this method of construction from Wood Smith magazine a long time ago it's a lot simpler than it looks and you really don't need any special tools for the core of the head I'm going to use a piece of three-quarter inch maple I've made mine about two and a half inches wide and I've cut it about twelve inches long but I'm only going to use about two and a half inches on each side the reason why I've got it longer is just so I have something to hold on to I'm drilling 1 and 1/2 inch holes on each side now I'm going to cut out both of these pieces on my table saw but I want them cut at a slight angle so I've set up my miter gauge to about a two degree angle you can see how these have a slight wedge so what I need to do now is just glue these two pieces onto one of the longer pieces make sure that you put these in the right way so that you have that wedge I'm not gluing this top piece on but I'm going to use it to clamp this together to give the head of the mallet some weight I usually fill these holes with those little lead fishing sinkers they're almost like bee bees but I thought I'd try to save some money this time and I'm just going to fill it with sand there's the mallet head all glued together now I can start to shape it round it over a little bit and to start with I've just tipped my table saw blade at about a 15 degree angle and I'll chop off the edges for the handle I've just glued together two pieces of oak and I want it to be a little bit bigger than this hole about an eighth of an inch all the way around it just so that I have room for a shoulder around the tenon and here is my tenoning jig I've got two two by fours that I just screwed together and it'll set down on top of my rip fence I can clamp my workpiece in just like this I've made a few shallow passes just to determine the correct fit so now that I've got that fit I know that my fence is set at the right distance that could raise the blade up now to the height of the mallet head and just shaving this down a little bit so I get a nice fit now I can come back to my tenoning jig and I just want to cut two slots all the way through here for the wedges and I don't want them to be quite as long as this tenon so I'm gonna lower my blade just a little bit shaping that handle is a lot of fun it's just a matter of sanding it until it has a good feel to it and it's kind of fun because everyone is going to be a little bit different to cut the wedges I've got a scrap piece of maple and I taken my table saw blade and I tipped it at a two degree angle well I'm glad I experimented with the sand in there but I could tell you it's nowhere near as heavy as this one where I put the the fishing sinkers in so I think it you're going to make this find some lead weights or BBS or something and you'll have a lot more heft to it and that's all there is to making them out it's really simple project and once you make it you're going to find all sorts of uses for it in your shop thanks for watching this video there's going to be no video next week I decided that needed a rest and I'm gonna take a week off I had a week off since Christmas so I'll see you in two weeks

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