How to Make a Battle Axe
There is no real need to own or make a battle axe in today's world other than as a hobby, unless you engage in reenactment or you are a live steel fighter. Many people are fascinated by fantasy and medieval weapons. This battle axe is a one-day project for anyone with at least one semester of welding shop experience. It is a challenge for a beginner to make an aesthetically pleasing, usable and durable axe. If you attend a fantasy convention or Renaissance Fair, you will see similarly constructed axes being sold by professional blademakers.
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Things You'll Need
- 1.25-inch diameter bar of 1018 steel
- 12-inch by 12-inch by 1/4 piece of 1018 steel plate
- MIG or stick welder
- Welding helmet and heavy leather gloves
- Leather welding apron
- 4.5-inch or larger right-angle grinder with 24 and 80 grit abrasives
- Coarse wire wheel
- Oxyacetylene torch with cutting and rosebud tips
- Soapstone marker
- Metal tank large enough to immerse your battle axe blade
- Super Quench (See Reference 2)
- 3 yards of leather thong
- Electrical tape
- Carpenter's glue
Instructions
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1
Design your axe for function and beauty using a soapstone marker on the steel itself, placing all pieces where they will make the most efficient use of all available steel. Remember to think and measure twice so that you can cut once.
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2
Don welding mask, welding apron and heavy leather work gloves before cutting or heating any of your steel.
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3
Use the oxyacetylene torch to cut the profiles of your battle axe blades along the outside of the soapstone lines. This leaves you room to grind your axe blades to shape without losing as much steel. Grind blade bevels with 24- and 80-grit abrasives using your right-angle grinder.
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4
Use your MIG or stick welder to attach the blades to your handle, using your choice of welds. Grind square points on each end of your 1.25-inch diameter bar of 1018 steel. Weld the washers on one end of your axe handle, far enough apart to be comfortable in your hand. Grind all welds until they are aesthetically pleasing.
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5
Heat the first two inches of one blade edge to dull orange, using your oxyacetylene torch with the rosebud tip. Immerse the heated portion of the blade and about an inch more of blade width in Super Quench solution. Repeat with the other blade or buttspike.
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6
Wire-wheel the entire piece to a brushed finish. You may use cold gun bluing or some other blackening agent to get a darker finish.
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7
Wrap your handle area between the two washers with electrical tape. Apply carpenter's' glue over the tape and allow it to dry until it is tacky. Wrap the handle with leather thong and finish sharpening your blade edges.
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Tips & Warnings
This article assumes that you have at least one semester in a high school or community college welding class before you should attempt this project. It also assumes that you have access to a fully-equipped welding shop, including all of the tools listed.
Do not weld or grind steel without proper eye protection and other safety equipment.
