Turning Old Into Gold. Restoration and Modification of a Rusty Axe

In this video I restore an old Rusty Collins axe into a brass plated and metal etched axe head. For the handle I do a woodworking inlay with walnut, maple and epoxy. This video shows woodworking and metalworking as well last metal etching and brass plating. I love metal and wood projects because they are so different yet combined into once piece. I got to use my brand new Harvey Table saw and various tools to create this piece.

Step 1: Check Out the Full Build With in Depth Instructions!

Check out the full video with in depth instructions!

Step 2: Find Your Vintage Axe

I purchased this axe for $5 at the local flea market. You can find these old axes pretty much anywhere! The first step is to take off the handle. For this there is no right or wrong way. I know I am not using the handle so I simply just cut it off and then use a hammer to get out the center.

Step 3: Sandblast, Grind, Polish

I start the restoration process by sandblasting the entire axe head. I then take my angle grinder with different grits to clean up the entire axe. I then use the orbital sander to refine even more. I go from 80 grit up to 400 grit before hitting the polisher.

Step 4: Brass Plating

I know I said this was "gold" in the description..... I lied..... I am actually brass plating this axe head. To do so, I heat up the metal and then using a brass wire attached to my drill I brush on the brass. The brass will melt onto the axe head leaving a brass plated finish.

Step 5: Metal Etching

I usually do a electro-metal etching technique. However in this case, the brass plating will not allow that to work. I instead use sulfuric acid to etch away the design. I use a vinyl cutout of my design to mask off the axe head, then submerge it into the sulfuric acid for around two hours.

Step 6: Time for the Handle.

I start by milling up my walnut. I use a hand plane to join one side, then rip it in my table saw for a glue up. Once dry, I get my Harvey Compass Miter gauge and set it to 45 degrees. I then do a series of cross cuts to get the design I want.

Step 7: Detailed Woodworking

I then bore out material by cross cutting sections of both side of the handle. I then use a hammer, chisel, file and sanding block to clean everything up and get the design I want.

Step 8: Maple Inlay With Epoxy

Using my cricut cutter I then cut out the same design as my axehead with a maple veneer. I then inlay the veneer onto my walnut cut outs. I then cast both sides in epoxy resin.

Step 9: Shape the Handle and Fit the Axe Head.

I then use my Harvey ambassador bandsaw to refine the axe handle. I then sand and use a 45 degree chamfer bit to make clean sharp side angles. I then have to fix the axe head so I use chisels, files and sandpaper for a perfect fit up. Lastly I finish the handle with some finish sanding to 600 grit and some oil based finish.