Forging your own axe for throwing involves several steps and requires a good understanding of metalworking as well as access to the appropriate tools and materials. The art of blacksmithing, which encompasses the techniques necessary to craft a metal axe, is complex and takes years to master, but with patience and practice, creating a simple throwing axe is certainly within reach for a motivated hobbyist.
Before beginning, safety is paramount. Safety goggles, gloves, an apron, and ear protection are essential when working with hot metal and machinery. Make sure your workspace is well-ventilated and you’re familiar with the operation of all your equipment.
First, you need to select an appropriate steel for your axe head. Carbon steel, such as 1055, 1084, or 5160, is typically used for axe heads because it can be heat treated to achieve a good balance between sharpness and durability. Stainless steel is not recommended for forging due to its properties and the difficulty in heat treating it effectively at home.
You will also need a forge, which can be a gas forge or a traditional coal forge, to heat the steel to a high temperature until it becomes red-orange and pliable. This state will enable you to shape the steel. An anvil and a selection of hammers, such as a cross-peen hammer, will be required to forge the metal to the desired shape.
Start by heating the steel and then hammer out the basic shape of the axe head. The key components you’ll form are the bit (the cutting edge), the cheeks (the sides that swell to give the axe its shape and heft), and the eye (the hole where the handle will fit). Forging requires patience as the steel will need to be reheated and worked several times to achieve the correct dimensions and symmetry.
Once the general shape is hammered out and the eye is punched or drilled, the axe head needs to be refined. This includes straightening, grinding, and sharpening using a combination of hand files, grinders, or even sandpaper. The symmetry and balance of the axe are crucial for throwing, so take your time in this stage to make sure everything lines up correctly and evenly.
After shaping, the axe head must undergo heat treatment, which is a two-step process of hardening and tempering. Hardening involves heating the steel until it is non-magnetic and then quenching it in water or oil to lock the steel into a very hard state. However, because this leaves the steel brittle, it must then be tempered. Tempering is done by reheating the axe head to a lower temperature and holding it there for a period of time, based on the desired hardness, before allowing it to cool slowly. This process relieves internal stresses and reduces brittleness.
Once the head is heat treated, you can attach a handle. The handle should be made of a strong wood, such as hickory, and properly shaped to fit comfortably in your hand and balanced to match the axe head. Carefully carve or sand the top of the handle to fit snugly in the eye of the axe head. The handle can be secured using a wooden wedge driven into a kerf cut in the end of the handle, expanding it against the inside of the axe eye.
The last step is sharpening the bit to a keen edge suitable for throwing. This can be done using sharpening stones, a file, or a belt sander with a fine belt. Consistent angle and symmetry on the edge are key for a reliable cut during throwing.
The entire process is technically demanding, requiring a keen understanding of materials and good craftsmanship. However, forging your own throwing axe can be a rewarding project that leads to a personalized tool you can enjoy in the sport of axe throwing. Remember, before using your freshly forged axe for throwing, practice the sport in a safe and controlled environment according to local regulations and safety standards.