Making a Replacement Handle for an Axe in the Woods

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Oct 18, 2008
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This past week, after once again watching IAWoodsman’s video on the versatility of the trailhawk, I was inspired to see what I can do with a hatchet. The part that I found particularly interesting was not the carving and splitting with the head, as that can be done just as easily with the handle still on, but the speed with which he made a replacement handle was impressive.

So often when it comes to axes we obsess so much about the handle being just right, that we start to think of the ability to make a handle for a hawk from a branch as some kind of magic. I got to thinking, how hard would it be to make a hatchet handle in the woods from a branch, using just the head of the hatchet. So here it is:

I used only a hatchet head and a baton to complete the project, in addition to the branch I used as a handle.

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I used the hatchet head to shape one end of the branch. This took me about 8 minutes. Since you do not have to reshape the whole handle, but rather only the part that will go into the head, it is fairly easy work. Start by shaping the very top part so that it fits in the head, and then follow that shape as a guide all the way down the carved portion.

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Once you know that the head fits, take the head and use it to split the shaped part of the branch. For this I did not use a baton, but just pushed the bit in.

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Once that is done, you have to do what I consider the hardest part-making the wedge. This is very easy to do with a knife, but when using a hatchet head, it can be cumbersome. The way I like to do it is take a longer piece and shape one end into a wedge. When that is done, I use the hatchet head and the baton to shorten it. It took me 3 minutes to make this one.

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Once you have the wedge, assemble your hatchet. The longer you leave the length of the wedge, the easier it will be to remove it later if you want to take off the head. Each time you remove it, you will probably need to make a new wedge as the process of driving it in usually damages it.

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Here is the finished product. It was made in less than 15 minutes. Of course, no one would ever consider using a handle made from a branch, but if we use the same standard we do for tomahawks, the project can be completed almost as easily. You could probably make a tomahawk handle in half that time, but at some point the advantage becomes more theoretical than practical.

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Here is what another 10 minutes with a knife gets you. It turned into a very usable hatchet, despite the low quality of the handle.

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In fact, the handle was attached so securely, that once I cut off the excess part of the wedge, I had to drill it out afterwards in order to free the head.

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This post shouldn’t be viewed as a critique of tomahawks, or to prove that hatchets are better. Each tool has its own advantages and uses. I only write this so that we don’t slide off the edge because we saw one very skilled person do something impressive with a tool. There are no magical answers and no perfect tools.

Ross
http://woodtrekker.blogspot.com/
 
Very nice and effective work. One question:
Since I would assume that the old, broken handle will still be wedged tightly in the head, how would you suggest removing the imbedded part of the old handle in the field?
 
Very nice and effective work. One question:
Since I would assume that the old, broken handle will still be wedged tightly in the head, how would you suggest removing the imbedded part of the old handle in the field?

My concern as well. This is what pioneers did back in the day to save weight, but that is what you'd call "field fitting" a handle, not "replacing" one - the latter would indeed imply getting the old handle out as well and that isn't really addressed here.
Really, that's one strong advantage of the "friction fit" tomahawks - getting a broken handle off requires nearly no effort.

Excellent tutorial.

Could it be burnt out without the head getting too hot?

Definitely inadvisable - the temper can start to be affected by the time the steel reaches as little as 200 degrees. Realistically, you'd take it home to do repairs but I guess the idea of this is a mock survival situation...

Given that scenario, burning out the wood might actually be the best course of action... burying the bit in damp soil to minimize the temper loss and using only coals or a minimal fire to burn out the handle. Even if the temper is ruined, you'd be saving a lot of time and energy (a necessity in a survival situation) doing it this way over pounding away at it to try and knock the broken handle out... also, fairly soft steel is still steel - it will still do the trick for splitting and chopping wood and is significantly better than having to fashioning an axehead out of stone.

If you have a saw in this given scenario though, you should probably try to pound it out the proper way. The trick is to saw off the handle flush with the head so that you can drive it out the top - the eye is larger there and you won't be working against the wedges which would tighten if you tried to drive it out the bottom. Without a saw though, pounding the handle out becomes very difficult - I suppose you could thin out the handle under the head using your knife so that you could drive it out the top, but that would be quite awkward and the chances of dinging up your knife is very high.
 
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Very nice and effective work. One question:
Since I would assume that the old, broken handle will still be wedged tightly in the head, how would you suggest removing the imbedded part of the old handle in the field?

Good question. Here I was thinking more of a loose handle situation, but it is possible to break a handle. If the head isn't glued on, it is fairly easy to just punch it out from the bottom with a stick after breaking the handle off with a rock or other object (assuming an extreme survival situation). If it is harder to get out, I wouldn't burn the head, but just use a coal from a fire the same way that you would burn out a spoon if you did not have a crook knife. That will keep the temperature of the bit fairly low.

The tomahawk has an advantage in that the head is very easy to pull out (if it is one of the models that are hafted from the bottom). On the other hand however, it is a loosely fitted head. There is an up and a down side to each one.

http://woodtrekker.blogspot.com/
 
Here is what another 10 minutes with a knife gets you. It turned into a very usable hatchet, despite the low quality of the handle.

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25 minutes to this is not bad at all, nice job. :thumbup:
 
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