Here is a simplified method to make a simple spear top Bardiche. It requires minimal equipment and a basic knowledge of forge welding. And of course, a forge big enough to work the bardiche. The same procedure can be used for any similar socket type axe weapon.
First make a drift from mild steel round stock to match the pole end shape. A tapered oval is preferred, but a tapered round works,too. Get a sheet of 1/4" steel (1050,5160,etc.) and cut out the basic profile of the blade and spike (A hawk shape). Cut out two long thin triangular pieces of the same type of steel about 1/8" thick.The height is the spear tip to socket length, and the base is half the circumference of the pole tip. These two pieces of steel will make the socket and spear. Start by forge welding the spear tip (triangle points) together for the length of the spear blade. Weld up solid , do the rough shaping, and move to the axe blade assembly. Open the unwelded part of the spear/socket piece to the weld joint. Clean up the inside with a file to remove scale. File/sand/grind the face of the axe blade to expose a clean surface. Grind/file a "V" in the top edge where the spear will meet the blade. Adjust fit to be as close as needed, and proceed to forge weld the spear to the blade. Once all welds are solid, use the drift to shape the pole socket. You can forge weld the socket sides together, gas/arc weld it, or leave the two pieces unjointed (use two or three bolts/rivets to attach the pole in this case).
Once the socket is shaped to the desired taper and all, go back and start forging out the blade and spike. While doing this you will fair in the joints of the spear/socket until it is a smooth rib in the center. Grind/sand/polish to as much final finish as you desire. Now (using a torch ) edge harden the blade. I would leave the spear soft,but you can harden it . The spike should be left soft. Temper at 350 . Etch the entire thing in FC to age it and give it that old metal look. Buff with 4/0 steel wool. Fit the pole. Oil/wax everything well.
Voila! you are the proud owner of a Bardiche.
If the project is purely for display use, you can just arc weld the parts together, forge /grind as needed,spray with black spray paint, and leave unhardened....but where's the fun in that.
If you don't have a big enough forge to do the spear/blade welds in, you can gas/arc weld the spear/socket to the blade. Use the appropriate welding rods. Or, worst case scenario, you could make iron rivets to rivet the spear/socket piece to the blade)
Hope this helps -
Stacy
