My friend is somewhat big sized, we call him viking.. or terminator.
He has 40th birthday coming, i wanted to make special gift to him.
Material is a 30cm long piece of railroad track. Piece weights 18kg.
After shaping blade weighted nearly 8kg, so its somewhat same weighted that sledge hammer.
Hardness of the track was 41 Hrc, because this is more like an decoration i didn't harden it after shaping.
180mm angle grinder:
125mm angle grinder:
Diy tools for shaping the handle:
Pipe / curve sander:
Abrasives i got from 3M, so this project was sponsored by them.
There are most likely alternative options too.
Step 1: Cutting "feets" Out..
I started with cutting feets of the track out.
I made this because that way i got little wider blade. ( about 3/4" / 20mm )
For the whole project i used only this one wheel, it lasted so long.
After cutting i grinded surfaces to same level.
This removes material quickly and is specially good when you need to sand surfaces to the same level.
Step 2: Cutting the Ends..
Next step was to cut out extra from the ends.
Because i wanted to get curvy shapes for the blades, i removed triangle shaped pieces from both ends.
Then i shared the piece to two parts, and made pre cut at the middle of the piece.
I left still enougn material that pieces stay together.
You might now notice that my intention is to shape both parts at the same time.
This gives symmetrical result easily.
To make these cuts i used that same 1.6mm cut off wheel.
My Metabo we 19-180 quick rt grinder cuts 60mm deep, so it was easy to cut trought from the top side of the rr-track.
Step 3: Shaping..
Because this is an axe.
I started to shape blade sharp.
I removed material with the 4.3mm grinding wheel
And the smoothened the surfaces with fibre disc.
Then i smoothened the sides of the axe. I wanted to get little more shapes to it,
so i grinded the sides little grooved.
Step 4: Making Slot for the Handle..
To make slot for the handle..
I started with cutting 30mm deep groove to the center of the top of the track.
Then i cut out two half V- shaped pieces from the both sides of the groove.
Overall widht of the groove is 40mm.
To make these cuts i used 2mm thick cut off wheel.
Continued by grinding the sides of the slots more rounded.
Made rough shaping with 4.2mm grinding wheel, then smoothened the surface with 36 grit fibre disc.
Shaped both sides and finished the bottom of the groove with hand file.
Step 5: More Shaping..
Because rr-track is somewhat thick i beveled the edges of the top part.
These bevels will be rounded later, but i tought its better to remove most of the extra at the early point of process.
I continued with the ends, removed most of the extra by cutting chunks out and the smoothened the cuts with
Finished curves with rotary tool and sanding drums.
I also wanted to get little grooves to the parts where the actual blade starts, i made these grooves by sanding them with sanding drums.
Step 6: Smoothening..
I tought that it would be easier to start finishing of the surfaces at this point.
I could get both parts done at the same time.
Because i had grinded the surfaces with 36 grit fibre disc, surface was somewhat rough.
I started finishing with 60 grit paper, removed all rough scratches and continued with 80 grit paper..
I switched to finer paper when i had removed all scraches made with the previous paper, until i was on grit 220.
For sanding i used sanding papers and backing with "velcro" connection.
Step 7: Welding Parts Together..
Now it was time to cut parts separated.
And weld them together..
One part that's not seen on the video, is that i preheated pieces to 100 degrees of celsius on the oven.
Then i tack weld pieces together and weld them togehter first from the inside,
this presses pieces together, and i don't need to use so big tack welds.
For welding i used stick welder and Esab ok 76.18 rod.
SFA/AWS A5.5 : E8018-B2
EN ISO 3580-A : E Cr Mo 1 B 42 H5
After welding interior, i continued with the welds on the top.
Its somewhat important to make all the welds when parts are hot.
To get nicer starts and ends for the welds, i weld pieces of L-track to both ends of the welding groove.
I started and end the welds on top of the L-track.
Step 8: Finishing..
I left the axe to cool down slowly.
Then i cut out the L-profiles, and smoothened the welds.
I made welds only to 10mm thick, i removed the extra material from the sides, and sand welds to the surface level
at the same time.
Step 9: Finishing Continued..
To connect the handle, i grinded outer end of the handle slot ( don't know how it should be called )
To cone shape, i used rotary tool and tungsten carbide cutter.
When installing the handle spline spreads the end of the handle against that cone shape. Spline is secured with epoxy. It gives firm and solid connection.
Then i removed all welding splatters with 220 grit paper, and smoothend all edges and grooves from the sides.
I finished the sides with 320 grit paper.
I sharpened the axe using "hard" sanding pad, started with 320 grit and continued to 600 grit.
Then it started to be sharp enough.
I made sharpenig so that the papers spinning direction is allways against the blade edge.
Carefully keeping the angle similar with the blade.
Step 10: Handle..
Step 11: Connecting the Handle..
To connect the handle i made 60mm deep cut to the end with hand saw.
Spline is hammered to this cut, and it spreads the sides of the handle against the edges inside the " handle slot ".
Because outer end is shaped to cone shape, connection is firm and secure.
Spline is secured with strong epoxy, it would hold nicely without too. But i wanted to be sure.
When epoxy was dried, i cut the extra out with oscillating tool. ( any saw works too )
Smoothend the cut by sanding. Toasted the end with torch ( nice black finish )
And oiled with linseed oil.
Whole handle is oiled with linseed oil, and blade is oiled with gun oil.
Step 12: Finished.. Nearly..
After 12 hours of work..
Most likely i could have made it much faster, but it was raining daily.
I had to use quite a lot of time for carrying things out of the rain and pack.
I used one:
1.6mm 180mm cut off wheel.
36 grit fibre disc.
One 2mm cut off wheel.
One flap disc.
One 4.2mm cutting / grinding wheel
40 grit sanding drums
Different grit Abrasive Discs
Overall cost about 20€
I hope you enjoy it.
Step 13: And the Stand for It..
Because this was going to be a gift.
I decided to make simple stand for it too, afterall.. this is mostly just a decoration.
Stand was very simple to make.
Step 1. Cut 10" long piece of H-beam.
Step 2 . Smash axe to one end of it.
Step 3. Weld a little mild steel plate to other end of the H-beam.
Very simple but working solution.
Thanks for watching!