Starting stock for a laminated felling axe?

[Leon Husock]

I'm looking to make a nice solid felling axe with a wide blade, and I'm not sure what dimensions to start with for the mild steel body. I was thinking .5x2.5"? Does anyone have experience with these?

 

[Stacy E. Apelt - Bladesmith]

You have two basic ways..
1) Use stock thick enough to slot by drilling and punching the eye. This will be a good bit of work and have expense in the cast iron drifts needed for someone who does not make axes regularly.

2) Use steel between 1/4" and 3/8" and make the head wrap style ... then weld in the bit. This is much simpler and can be done by someone with basic forge welding skills. The eye will be easier to shape, and a home forged drift will work. No need to make the poll flat unless you want it that way.
Weld the bit on with MIG/TIG all the way around while clamped firmly in place. Then forge weld it solid.
If you want a flat hammer poll, TIG/MIG weld up the butt and forge weld it solid , then weld up the bit as before.

 

[Leon Husock]

You have two basic ways..
1) Use stock thick enough to slot by drilling and punching the eye. This will be a good bit of work and have expense in the cast iron drifts needed for someone who does not make axes regularly.

2) Use steel between 1/4" and 3/8" and make the head wrap style ... then weld in the bit. This is much simpler and can be done by someone with basic forge welding skills. The eye will be easier to shape, and a home forged drift will work. No need to make the poll flat unless you want it that way.
Weld the bit on with MIG/TIG all the way around while clamped firmly in place. Then forge weld it solid.
If you want a flat hammer poll, TIG/MIG weld up the butt and forge weld it solid , then weld up the bit as before.

This is exactly what I wanted to know! Thanks so much!

 

[Mark van Elteren]

Not sure about a felling axe, but I have made a couple of carving axes (went on a course with Nic Westermann, then did a few at home). I did it out of a solid piece of tool steel, but you could split the end and insert a bit with the same basic method.

The most difficult part is making the drift. I did it myself with nothing but a hand hammer, and it was quite a PITA. If you have a striker or power hammer/press, that should be no problem.

Regarding size, starting with weight might help figure it out, but I have no experiece with axes this big.