From a old Hickory pallet to a new wooden Mallet. This mallet has a good handle and a good size mallet head. Filled with melted lead to give you a nice feel and dead blow effect. Check out how I take a scrap piece of pallet lumber to a useful tool and a must have in the shop.
Started with a scrap piece of hickory that came from a pallet. 2.5″ x 2.5″ x 12″. Turned the blank round to a large dowel rod.
I started by using my hand to lay out the lines, after all it need to fit my hand. Then I started turning the handle portion first. I want a seamless flow through the hilt of the mallet.
The head couldn’t be easier. I used the full width of the blank and tapered down to where the handle began. This was a very small tapper. Then I took a 3/4″ bit to drill a hole into the top as far as I can go. It ended up being about 5″ deep. This is used to fill up with lead.
Make a slight tapered plug that fits into the hole drilled in prier step. Flip the handle and use tail stop to hold the piece. Finish the bottom of the handle.
You will need some sort of a metal funnel. I didn’t have one, so I made one from a pop can. I cut the can body of a pop can out and rolled it into a funnel shape. I used a piece of foil tape to hold it. Then melted the fishing line weights down to a liquid and pored the lead into the 3/4″ hole at the top.