Make a Custom-Fit Mallet Handle

I’ve discovered an easy way to shape my tool handles to fit my hand. I have used this approach on hammers, mallets, and replacement saw handles, as well as custom drawer pulls, tool totes, and a custom recurve bow.

making custom tool handles shaping custom tool handles

To create a form, I simply soak and squeeze standard paper towels, adding and removing towels until the form looks good and feels perfect. From there, I trace the form onto my handle blank and cut it to shape at the bandsaw. I do the final shaping and finessing with rasps and a sanding drum, checking the feel as I go.


Illustrations by Dan Thornton
From Fine Woodworking issue #286

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Easy-to-understand step by step instructions. Every plan has simple “hold-you-by-the-hand” instructions that will assist you to complete your projects quickly.