There's actually not much to tell, but this simple project came together nicely and turned out looking spectacular. I look forward to many years of use, each time being reminded that I made this tool.
The head is 1.250" 360 Brass, cut to length and faced with very slightly convex faces. A 0.625" slot was cut through the head to accept the handle. After cutting the slot I roughed up the inside of the slot a bit with a rotary tool and burr, as well as tapering the slot a bit.
Carving of the handle began with some unknown hardwood I had lying around. It had nice grain and seemed very strong; certainly good enough for a hammer handle. I rough cut it to shape using the bandsaw, then worked it to the final shape using a draw knife, spokeshave, and belt sander. Fitting the handle to the head is a bit of an art. There are lots of videos on YouTube showing the process. I opted for a somewhat loose fit to start, with a bandsaw cut down the long way to accept a wedge. Everything got a good coat of epoxy when fitting up and driving the wedge in, and the remaining space was also filled. I used tape underneath to prevent any dripping through.
Finally it was all finished off with some stain and clearcoat. I didn't go crazy with the finish because I don't like slippery hammers. The wood is sealed but still somewhat rough for grip.
Oh, and hey if I don't end up getting that granite flat (see my other recent post) at least it makes a great backdrop for taking pictures.
