One of the first things we ever made out of recycled plastic were mallets. To this day we still use our beaten up old HDPE mallet and it works like a dream as it's such a dense material.

We've tried a number of different ways to make these, but we wanted to work out the easiest method possible. To do this, all you really need is a tin can and a heat gun. You just need add your HDPE plastic in bit by bit, squishing it down and applying heat until your tin is nice and full. Once it's completely full you can push your handle in place, add some scrap wood with a hole in to help apply clamping pressure and clamp it all down.

Once cooled, you just need to take of the tin and you've got yourself an awesome little mallet! If you want it to look a bit prettier, you can pop it on the lathe like we've done here, but if not, it works perfectly as is.

Be sure to let us know if you give one a go!

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