Making a wooden mallet from 2 feet of a 2x4. There are a lot of mallet videos floating around out there, most of which involve a wedged through handle, which are great, but I wanted to try something a little different.
I routed a dovetail in the two sections that make up the mallet. I used southern yellow pine - a very hard species of pine which can be found at most local home centers.
Update: One year later, and the mallet is still holding up great, I use it nearly every day.
Tools & products used:
Delta Unisaw table saw
DEWALT DW716 Miter Saw
Rockwell 14" Bandsaw
Makita random orbital sander
DEWALT DWE6000 Trim router
Titebond original Wood Glue
Varathane provincial wood stain