Here's an interesting turning
project which results in a useful wooden mallet.
with a block of wood that's significantly larger than the mallet
head you want. I used poplar here because I have to have samples
of the steps along the way so I chose a cheap wood. For a real
mallet, use a better wood than poplar.
Note that I've squared the ends -
cut them off on the miter saw really - then used the ends to
draw a line along one side in the middle of the block. I've
taken the line down both faces. Then, mark the center on each
end, and along the top of the block.
On each side of the center mark on
each end, I put two additional marks. These will be your offset
I spaced them 5/16" from the center
but 1/4" will do. The more the offset, the more "bent" the
mallet will be.
Then drill a hole through the top
of the block. I think I used a 3/4" drill but 7/8" would be
okay, also. This is where your handle will go.