Prerequisites:
Basic Metal Shop SBU: MTL103 at the TechShop
Basic Wood Shop SBU: WOD101 at the TechShop

Materials:
• Hammer Head (this one is a French Cross Pein, hand forged out of tool steel!)
• Wood • approximately 1.5” x 2” x 12” (I used TulipWood mostly because I had it, but I would recommend Hickory for it’s strength and flexibility)
• Tung Oil
• Scrap steel (for wedge)
• Slow cure epoxy

I made it at TechShop! For more about TechShop, check out their site: http://www.techshop.com

Step 1: Cut Material to Size With Band Saw

• Use the band saw to cut your material a 1.5" x 2" x 12" block.
• Next draw the profile of the hammer handle and use the band saw rough out the shape.

Step 2: Shaping

• Use the belt/disc sander to shape the general profile your handle.
• Use a hand rasp or file get into curves and to refine the shape.
• Use sandpaper to smooth the surface of the wood.

Step 3: Tung Oil

• Apply Tung Oil with a soft cloth to finish wood.

Step 4: Steel Wedge

• Find a scrap piece of the sheet steel and cut it down (using the metal band saw) to an appropriate wedge size.
• Use the bench grinder to shape the edge of the wedge.

Step 5: Attaching the Handle and the Hammer!

• Drive the wedge in with a mallet.
• Glue the wedge in place with a slow curing epoxy (slow curing epoxy causes the wood to expand and hold the hammer in place more securely).

I made it at TechShop! For more about TechShop, check out their site: http://www.techshop.com