Introduction

• Replacing an axe head can be a valuable skill for anyone who frequently uses axes, whether for forestry, woodworking, or outdoor activities.
• Over time, axe heads may loosen, get damaged, or need an upgrade, and knowing how to replace them ensures safety, effectiveness, and longevity of the tool.

Step 1: Remove the Old Axe Head

• Tools Needed: Hammer, punch, handsaw, mallet, and safety equipment (gloves, safety goggles).
• Procedure:
  1. Secure the axe handle in a vice or workbench to keep it stable.
  2. Remove the Wedge: If a wooden or metal wedge is present in the top of the axe handle, use a punch or screwdriver to tap it out carefully.
  3. If the handle is broken or jammed inside the head, saw off the handle just below the axe head to make removal easier.
  4. Insert a punch through the top of the axe eye and gently tap with a hammer to drive out the remaining piece of the handle. Be patient and ensure not to damage the eye of the axe head during this process.

Step 2: Clean and Prepare the Axe Head

• Thoroughly clean the inside of the axe head eye with a wire brush to remove any dirt, rust, or leftover wood.
• Inspection: Examine the axe head for any cracks or deformations that might affect the handle's fit or the tool's balance.

Step 3: Measure the Axe Head Eye

• Accurate measurements of the axe head eye are crucial for selecting a handle that will fit securely.
  • Tools Required: Calipers or a measuring tape.
  • Width Measurement:
    • Measure the eye's width at both the top and bottom of the head to account for any taper.
    • Note these measurements, as the top is typically wider than the bottom to ensure a tighter fit when the handle is inserted.
  • Length Measurement:
    • Measure the length of the eye (front-to-back) at both the top and bottom, again noting any taper.
  • Shape Assessment:
    • Some axe eyes may be oval or slightly irregular. It’s essential to choose a handle that closely matches the eye's shape for the best fit.
  • Pro Tip: It’s a good idea to record these measurements on paper or your phone for easy reference when selecting a new handle.

Step 4: Choosing the Right Handle

• Selecting the Wood:
  • Hickory is the most recommended wood due to its strength, flexibility, and shock absorption.
  • For historical or aesthetic purposes, ash can also be used.
• Length and Style:
  • Match the handle length with your intended use: longer handles for splitting axes and shorter ones for hatchets.
  • Decide between straight and curved handles depending on the axe type and personal preference.
• Matching Handle Size:
  • Ensure the handle's eye size matches your measurements. Handles typically come pre-shaped but may require minor adjustments.
  • Where to Buy: Reliable sources like Axeman.ca offer high-quality handles in various sizes for a range of axe heads.

Step 5: Fitting the New Handle

• Initial Fit:
  • Slide the new handle into the axe head eye from the bottom. It should be snug and require some pressure to get it to the right depth.
  • Mark the area where the handle sticks out above the head.
• Shaping the Handle:
  • Use a rasp or spokeshave to shape the handle end gradually, aiming for a tapered fit that sits tightly in the eye.
  • Remove small amounts of wood at a time to avoid over-shaping.
• Check the Fit:
  • The handle should enter the eye until it’s seated securely without wobbling. Ensure the top of the handle is flush with the top of the axe head.

Step 6: Securing the Axe Head with a Wedge

• Wooden Wedge:
  • Tap a wooden wedge into the kerf (pre-cut slot) at the top of the handle using a mallet. This spreads the handle inside the axe eye, creating a tight fit.
  • Trim off any excess wood from the wedge and handle.
• Metal Wedge:
  • Drive a metal wedge perpendicular to the wooden wedge to further expand the handle and lock the head in place.
  • Use caution when driving the metal wedge—too much force can split the handle.

Step 7: Finishing Touches

• Sanding:
  • Smooth down any rough areas on the handle with sandpaper to improve grip and comfort.
• Sealing the Handle:
  • Apply boiled linseed oil or another finish to the handle to protect it from moisture and improve durability.
• Final Inspection:
  • Ensure that the axe head is firmly attached and doesn’t move when swung. If there’s any looseness, consider adding another wedge or repeating the fitting process.

Safety Tips

• Regularly check your axe for signs of wear, especially if it is used in heavy-duty tasks.
• Always wear safety gear when working on the axe, particularly eye protection.

Conclusion

• Emphasize that proper measurement and fitting are essential for a safe and functional axe.
• Encourage readers to practice patience and precision when replacing their axe head for the best results.
• Suggest checking out Axeman.ca for high-quality handles that fit their needs.