Anyway, I went looking for a tool to restore when it hit me. I have this favorite kind of hammer. I use this one brand and style for everything except framing up walls. So when i brake one I just go out and get another one just like it. I save the broken heads because I can't stand to throw things away. I never thought about fixing it until this awesome contest.
Well as usual i did things a little different. I used pallet boards for the handle and powder coated the head. I really love how it turned out and I hope that you like it too. Enjoy
Step 1: Clean Up the Head
I broke this particular hammer fairly soon after I got it while building a goat barn. It wasn't the hammers fault, I was pretty rough on it. Anyway the head was in pretty good shape I just needed to clean it up a bit. I went to my bench grinder to clean up all the rust. It doesn't take long to find clean steel. There was some powder coat which was a little harder to get off but with a little presence I got it. There were some nooks and crannies that I had to use an angle grinder with a wire bush to clean up, but when I finished it sparkled like new!
Step 2: Powder Coat
I've had a powder coater for a while but I've never used it until now. I wanted the head to be two toned so I taped off the part that I didn't want to be green. There is two ways to do this. You can buy the high temp tape so you can cook it with the powder or you can just use painters tape and take it off before you put it in the oven. That's what I did because I didn't want to buy expensive tape.
I am not expert on powder coating because this was my first attempt but there are plenty of good instructables on the subject. I throughly coated the head with powder and after disconnecting it from the power, carefully removed the tape. The great thing about powder coating is if there is powder somewhere that you don't want it you can just brush it off.
After you get the head ready you need to bake it in an oven. You want to make sure that you don't use a oven that you use for food. The process gives off some fumes that you don't want to mix with your food. I baked it at 400 degrees for about 25 mins. Let it cool slowly and you have a beautiful hammer head!
Step 3: Glue Up Pallets
I used two different boards so there would be some contrast in the handle. Run both boards through the planer so all sides are smooth. This is important so you have a seamless look when you glue the boards together. Glue and clamp the boards and let smith over night.
Step 4: Shape Those Pallets
To shape the handle I worked for a long time on the bench sander. I made sure that everything was flush and then started working on the contour. I took off the rough edges on the bench sander and then moved on to a palm sander to finish it off.
When you have the desired shape. Hand sand from 80 to 320 grit.
Step 5: Secure the Head
I made wedges with a piece of scrap steel. I cut them with an angle grinder and a cut off blade. Then I went to the bench grinder to sharpen the wedge.
You drive the wedges into the handle to keep the head on. Drive them in until the wood expands tight inside the hammer head. Cut off the excess and sand the top flush.
Step 6: Epoxy Finish and Enjoy
I used bees wax and orange oil furniture conditioner for the handle. It protects the wood and brings out some of the natural colors. And that's it folks... An awesome hammer restoration that you can be proud to hang from your tool belt.
Step 7: That's All Folks
I hope you enjoyed this instrutable and as always... Thank you so much for reading!!