Forging a throwing axe is a bit more complicated than forging a knife or sword. But with the right tools and techniques, you can craft a quality throwing axe that will last for years to come.
In this article, we will go over everything you need to know to forge a throwing axe from start to finish.
So, grab your hammer, and let’s get started!
Choosing the Right Steel
The first step in forging a throwing axe is selecting the right steel. You need to consider several factors such as hardness, toughness, and edge retention.
With those factors in mind, choosing a high-carbon steel like 5160, 1095, or 1060 is an excellent option. You can even repurpose materials such as leaf springs from vehicles for an eco-friendly alternative.
Essential Tools for Forging a Throwing Axe
Before we get started, it’s important to make sure you have the proper tools to forge a throwing axe. You may already own most of the tools in the chart below, however, I also added some alternatives in case you don’t.
| Tool | Basic Tool | Alternative |
|---|---|---|
| Forge | Gas Forge | Charcoal Forge |
| Anvil | Quality Anvil | Railroad Track, Flat Steel, or Concrete Slab |
| Hammer | Blacksmith’s or Cross-Peen Hammer | Nail Hammer or Sledgehammer |
| Tongs | Blacksmith Tongs | Heavy-Duty Pliers or Vise Grips |
| Files and Grinders | Belt Grinder | Angle grinder, Files, or Sandpaper |
| Heat Source for Tempering | Electric or Gas Oven | Forge, or MAPP Torch |
| Quenching Tank | Dedicated Quenching Tank with Quenching Liquid | Heat-Resistant Container with Quenching Liquid |
Check out our Guide on the Essential Tools for Forging a Throwing Axe for more details on these tools and where to find them.
How to Forge a Throwing Axe Head
Now that you’ve got your tools and steel ready, it’s time to start forging your axe head.
Here’s a step-by-step process:
Step 1: Preparing the Steel
Before you start forging, you’ll need to cut your steel to the appropriate size for your axe head. This will depend on the size and design of the throwing axe you want to create.
A typical throwing axe head weighs between 1 and 2 pounds, so plan accordingly when selecting your steel size.
Step 2: Heating the Steel
Initial heating: Place your steel in the forge and heat it until it reaches a bright orange or yellow color, which is about 2000°F (1093°C). This is called the “forging temperature” and will make the steel malleable enough to shape.
Maintaining heat: As you work, the steel will cool and become less malleable. Reheat the steel in the forge as needed, always keeping it within the forging temperature range.
Step 3: Shaping the Axe Head
Forming the cutting edge: Begin by forging the cutting edge of the axe head. Use your hammer and anvil to taper the edge, making it thinner and sharper. Be mindful of maintaining an even thickness along the edge.
Creating the beard (optional): If you want to add a beard (a curved section below the cutting edge) to your axe head, now is the time to do it. Use your hammer to draw out the steel and create the desired curve.
Forging the eye: The eye is the hole where the handle will be inserted. To create the eye, fold the steel around a mandrel or drift (a tapered rod) and hammer the steel until the two sides meet. This will create a circular or oval hole in the axe head.
Step 4: Refining the Shape
Initial shaping: After forging the basic shape of your axe head, use a file or belt grinder to smooth out any hammer marks and refine the overall form.
Defining the cutting edge: Further refine the cutting edge of the axe head by removing any remaining rough spots or unevenness. Be cautious not to remove too much material, as this will weaken the edge.
Step 5: Heat Treating the Axe Head
Hardening: To increase the axe head’s durability and edge retention, it must be hardened. Heat the axe head until it is no longer magnetic (around 1475°F or 802°C), then quickly quench it in oil or water.
Tempering: After hardening, the axe head will be brittle and prone to cracking. To increase its toughness, you need to temper it. Heat the axe head to a lower temperature (around 400°F or 204°C) and hold it at that temperature for a specific period, typically 1-2 hours.
For a more detailed guide on tempering, check out our ultimate guide to tempering a knife.
Step 6: Sharpening the Edge
Finally, it’s time to sharpen your throwing axe’s cutting edge. Use a file, belt grinder, or sandpaper to achieve a sharp, even edge. As a throwing axe, the edge doesn’t need to be razor-sharp but should be honed enough to provide a clean cut when it strikes its target.
With your axe head now forged, refined, and sharpened, you’re ready to work on your handle.
How to Craft a Throwing Axe Handle
A throwing axe isn’t complete without a handle! You can either buy a premade handle or make one yourself.
To make your own handle, follow these steps:
Selecting the Handle Material
When it comes to handle materials, hardwoods such as hickory, ash, or maple are ideal choices due to their durability and shock absorption.
Avoid softwoods, as they may not withstand the force of throwing and could potentially break.
Shaping the Handle
Cut the handle blank: Begin by cutting your chosen wood to the appropriate length for your throwing axe handle. As a rough guideline, a handle length between 12 and 20 inches is common for throwing axes.
Rough shaping: Mark the shape of your desired handle on the wood blank using a pencil. Then, use a saw, rasp, or belt sander to remove excess material and create the basic shape of the handle. Focus on creating a comfortable grip and ensuring the handle tapers towards the top to fit the eye of the axe head.
Shape the shoulder: The shoulder is the part of the handle that sits flush against the axe head. Use a rasp or belt sander to create a flat area on the handle that will align with the bottom of the axe head.
Create the tenon: The tenon is the top portion of the handle that fits into the eye of the axe head. To create the tenon, measure the size and shape of the eye and mark the corresponding dimensions on the handle. Use a rasp or belt sander to remove material until the tenon fits snugly within the eye.
Finishing the Handle
Sand the handle: Once the handle is shaped, use sandpaper to smooth out any rough spots and even out the surface. Start with a lower grit sandpaper (e.g., 80-100 grit) and work your way up to a finer grit (e.g., 220-320 grit) for a smooth finish.
Apply a finish: To protect the wood and enhance its appearance, apply a finish such as boiled linseed oil, tung oil, or a polyurethane coating. Follow the manufacturer’s instructions for application and drying times.
Assembling Your Throwing Axe
Now that you have both the axe head and handle ready, it’s time to put them together. Here’s how:
Fit the handle: Insert the handle into the eye of the axe head. Make sure it fits snugly and securely. If necessary, you can use a mallet to gently tap the handle into place.
Secure the axe head: To prevent the axe head from coming loose during use, you can use a wooden wedge to secure it. Drive the wedge into the top of the handle, inside the eye, so that it expands the wood and locks the axe head in place.
Final touches: Give your throwing axe a final inspection and make any necessary adjustments. You can also personalize your axe by adding decorative elements, engravings, or even a custom leather sheath.
Helpful Tips for Forging Your Throwing Axe
Now that you have a detailed breakdown of the forging process, let’s explore some helpful tips to make your journey as a beginner blacksmith even more enjoyable and successful.
Safety First
Always prioritize safety when working in your forge. Wear proper safety gear such as gloves, goggles, and a respirator when needed. Additionally, ensure your workspace is well-ventilated to avoid inhaling harmful fumes.
For more safety information, refer to our article on knife-making hazards, injuries, and safety.
Start Simple
As a beginner, it’s essential to start with a simple design for your throwing axe. This will make the forging process less challenging and help you develop your skills before moving on to more complex designs.
Take Your Time
Forging a throwing axe requires patience and precision. Don’t rush the process, as this can lead to mistakes and an inferior final product. Take your time and enjoy the experience of creating something with your own hands.
Learn from Mistakes
Mistakes are a natural part of the learning process, so don’t be too hard on yourself if your first throwing axe doesn’t turn out perfectly. Instead, use these mistakes as learning opportunities to improve your skills for your next project.
Seek Advice and Inspiration
Connect with other blacksmiths and knife makers to share tips, advice, and experiences. You can find online forums, social media groups, or local workshops where you can ask questions and gain valuable insights. Don’t be afraid to ask for help or guidance.
Keep Your Tools in Good Condition
Maintaining your tools is crucial for successful forging. Regularly inspect and clean your tools to ensure they are in optimal working condition. A well-maintained tool will make your work more efficient and enjoyable.
Frequently Asked Questions
Yes, forging a throwing axe is a suitable project for beginner blacksmiths. It provides an excellent opportunity to practice basic forging techniques, heat treatment, and handle-making while creating a functional and enjoyable tool.
High carbon steel, such as 5160, 1080, or 1095, is ideal for forging a throwing axe due to its durability, edge retention, and ease of heat treatment. These types of steel are more forgiving for beginners and provide excellent performance for a throwing axe.
The essential tools for forging a throwing axe include a forge, an anvil, a hammer, tongs, and various files or grinders for shaping and sharpening the axe head. You will also need materials for crafting the handle, such as a hardwood blank, saws, rasps, and sandpaper.
The time it takes to forge a throwing axe can vary depending on your experience, tools, and the complexity of the design. For a beginner, forging a simple throwing axe can take anywhere from a few hours to a couple of days, including the time for heat treatment and handle crafting.
The ideal weight for a throwing axe can vary depending on personal preference and the specific event or competition. Generally, a throwing axe should weigh between 1 and 2 pounds, with the head accounting for the majority of the weight.
To ensure proper balance, focus on creating a well-proportioned and symmetrical axe head. When attaching the axe head to the handle, make sure it fits snugly and securely. The handle should be slightly tapered towards the top to accommodate the eye of the axe head. Finally, test the balance by holding the axe at the point where the handle meets the head and ensuring it feels comfortable and balanced in your hand.
Some common mistakes to avoid when forging a throwing axe include overheating the steel, which can cause it to become too brittle; not properly heat treating the axe head, resulting in a lack of hardness and edge retention; and creating an unbalanced or poorly fitting handle, which can negatively affect the throwing performance.
To maintain your throwing axe, regularly inspect the handle and axe head for any damage or wear. Keep the cutting edge honed and free of nicks or chips. Additionally, clean and oil the axe head as needed to prevent rust and corrosion. If the handle becomes loose or damaged, replace it to ensure safe and effective use.
Yes, you can use a store-bought handle for your throwing axe, as long as it fits the eye of your axe head properly and is made from a suitable hardwood such as hickory, ash, or maple. However, crafting your own handle allows for customization and a better fit for your specific axe head.
Final Thoughts
Congratulations! You’ve successfully forged your very own throwing axe. But remember, creating the axe is just the beginning. To truly master the art of axe throwing, you’ll need to practice your technique and develop your skills. So, grab your new axe and start honing your inner warrior!
As a beginner, you’re bound to make some mistakes along the way, but don’t be discouraged! We all have to start somewhere.
Now that you’ve created your first throwing axe, the world of blacksmithing and knife-making is wide open for you to explore. Keep learning, experimenting, and honing your skills. Who knows, maybe one day you’ll be the one sharing your knowledge and experiences with others!
