1. Bend each end over and onto itself about 5/8". This will later make the poll.
2. Bend the entire piece in the middle so that the ends that you bent over are on the inside. The center of the bar is what will eventually make the blade. Apply flux to the entire piece after bending it.
3. Now forge weld the the poll and the face. Leave an un-welded section between the poll and face for the eye.
4. Begin forging the blade to the shape you enjoy. Use a cross peen to make the face wider. To refine the profile you can set the head upside down on the face and hammer down, or set it right side up on the horn and hammer down.
5. Now drift the eye. Do this at a high heat to keep from breaking the welds or sucking the eye down. Use a tapered drift (about 1/8" or 3/16" of taper per inch of length), and drift from both sides. This gives an hourglass shape to the inside of the eye that keeps the handle held in more tightly.
After forging, clean up the profile some if you like, establish the edge, then heat treat it. Most hatchets and axes should be convex ground.
These are fun to make, and don't take long to do. Have fun....
Edited by Murch, 10 January 2007 - 04:27 PM.