Wow! This one is not going to languish in the bed of your pickup truck in the aftermath of exerting that amount of time and effort. One thing about being slow and methodical (and not using power tools) is that the likelihood of making a 'real mess' is almost impossible. I like that and can say; Good for you!
I like what was said here. I know you can work much faster with grinders and such, but there is something satisfying and therapeutic about using the hand tools. It makes the final product that much more pleasing. Now, if I was a working forester, I'm sure I would need a different approach.
I have found that files can make a difference. Nicholson makes a file called a Magicut. For rough work, like filing butt mushrooms, it is faster without being too rough. You can finish off with an 8" bastard file. I also use lots of sandpaper, from 80 to 2000 grit. Strictly personal choice, but I like to finish the poll and the edge, once its sharpened, with a good sanding, up to 2000. I like the shine it leaves on the two ends of the axe. I am now more inclined to leave the patina now rather than wanting to sand the whole head, unless its covered in rust.
I have also found that the 4 in hand is not so useful as a shop tool, although for bush work, it makes sense to carry one file rather than 4. I have heard that a good ferrier's rasp is great for working on handles. I am going to try this as shaping and paring down handles, especially the Garants we get in Canada, takes a lot of time.
One thing I learned the hard way too: take the time to see that the handle fits nicely into the eye before hammering the bottom of the handle to set it. When I first started, I wanted to get a super tight fit between the handle and the eye. In the process, I made it too tight and couldn't get good wedge penetration, and I cracked a couple of nice handles trying to pound them in.
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