Hey guys, thanks for the input!
Regarding Texascarl's thoughts on blade shape, it's certainly a possibility. Losing the upper curve would greatly simplify casting. One of the problems we're having with the design is placement of the risers. A flat line across the top would make it a lot easier to grind off the stubs. On the other hand, I really like the look of it now. I don't think it will be as functional with the more narrow head, at least not for everyone. The narrow profile will penetrate more, but in my experience it is more likely to get stuck on the wood. I usually want to make a cut across the stick rather than into it. Depending on your style of cutting, there may be an advantage to using the part of the edge that slopes back to the handle as he says, but for other styles it's a disadvantage. I was roughing out a handle for an early trade axe a couple of days ago and I tried the method shown in Wille Sundqvist's book "Swedish Carving Techniques". He uses an axe with an edge that slopes away from the handle. It looks really awkward until you try it. The idea is that the edge contacts the wood with a slicing action rather than straight on. I didn't grind a new head, but just used a "broken wrist" grip so the edge sliced in at an angle. It worked well enough I'll probably either grind a head, or make a seriously bent handle for a woodworking axe. Anyway, the full curve gives you both options. I don't think weight will be much of a problem. The single edge version (the Allan Hunter's Belt Axe) is about 11 ounces with the 14" handle.
We thought about a striking surface on the side of the head, if only as a place to put the risers. I don't think I like the idea. I really want to differentially harden the heads for durability, and it's not practical to do this with center striking surface. It looks awkward and I'm not sure it would be that useful. I have these surfaces on one or two of my hammers and I can't recall ever using them. You can usually find a rock anyway. In a pinch you could use the side of the head even without a defined striking surface.
I think we're going to go with the same handle as the hunter's belt axe. As mentioned it's a lot easier than having a new handle turned. I like the tomahawk style better than the ball peen hammer style. There are no wedges to fool with, it cannot come off, doesn't get loose, and, as was mentioned in the earlier Nessmuk thread, it's a lot easier to replace in the field. Down the road I may see if I can get them in longer lengths for two handed use, but I a bit dubious. The Slasinski 'hawks come with 22" handles, and are about the same weights as the current project. (The "Kid's 'Hawk" weighs less than 14 ounces, the Flared 'hawk just over 15 ounces, with handles) Most customers cut the handle back. Even with the light weight they find the long handles awkward to carry. Any other thoughts on this?
Regarding Texascarl's thoughts on blade shape, it's certainly a possibility. Losing the upper curve would greatly simplify casting. One of the problems we're having with the design is placement of the risers. A flat line across the top would make it a lot easier to grind off the stubs. On the other hand, I really like the look of it now. I don't think it will be as functional with the more narrow head, at least not for everyone. The narrow profile will penetrate more, but in my experience it is more likely to get stuck on the wood. I usually want to make a cut across the stick rather than into it. Depending on your style of cutting, there may be an advantage to using the part of the edge that slopes back to the handle as he says, but for other styles it's a disadvantage. I was roughing out a handle for an early trade axe a couple of days ago and I tried the method shown in Wille Sundqvist's book "Swedish Carving Techniques". He uses an axe with an edge that slopes away from the handle. It looks really awkward until you try it. The idea is that the edge contacts the wood with a slicing action rather than straight on. I didn't grind a new head, but just used a "broken wrist" grip so the edge sliced in at an angle. It worked well enough I'll probably either grind a head, or make a seriously bent handle for a woodworking axe. Anyway, the full curve gives you both options. I don't think weight will be much of a problem. The single edge version (the Allan Hunter's Belt Axe) is about 11 ounces with the 14" handle.
We thought about a striking surface on the side of the head, if only as a place to put the risers. I don't think I like the idea. I really want to differentially harden the heads for durability, and it's not practical to do this with center striking surface. It looks awkward and I'm not sure it would be that useful. I have these surfaces on one or two of my hammers and I can't recall ever using them. You can usually find a rock anyway. In a pinch you could use the side of the head even without a defined striking surface.
I think we're going to go with the same handle as the hunter's belt axe. As mentioned it's a lot easier than having a new handle turned. I like the tomahawk style better than the ball peen hammer style. There are no wedges to fool with, it cannot come off, doesn't get loose, and, as was mentioned in the earlier Nessmuk thread, it's a lot easier to replace in the field. Down the road I may see if I can get them in longer lengths for two handed use, but I a bit dubious. The Slasinski 'hawks come with 22" handles, and are about the same weights as the current project. (The "Kid's 'Hawk" weighs less than 14 ounces, the Flared 'hawk just over 15 ounces, with handles) Most customers cut the handle back. Even with the light weight they find the long handles awkward to carry. Any other thoughts on this?