An axe is an essential tool for woodworkers, campers, and anyone who needs to cut or split wood. But over time, even the best axe heads can become dull, chipped, or damaged beyond repair. Replacing the axe head is often more cost-effective than buying a new axe, especially if you have a quality handle you want to keep using. In this comprehensive guide on how to replace an axe head, we’ll cover everything you need to know – from choosing the right replacement head to properly installing it on your existing handle. We’ll also share important axe maintenance tips to keep your newly refurbished tool in top shape.
Contents
Why You May Need to Replace an Axe Head
There are several reasons why you may need to replace the head of your axe at some point. Understanding these will help you know when it’s time for a new axe head replacement.
The Blade is Severely Dull or Chipped
One of the most common reasons to replace an axe head is when the blade becomes extremely dull. A dull blade requires significantly more effort to cut and can be dangerous. Over time, even with regular sharpening, the metal gets worn down to the point where the entire head needs replacing.
In addition to dulling, the blade can also become chipped from striking objects like rocks or nails in the wood. Chipped blades are compromised and pose a safety hazard. Small chips can be filed out, but severe chipping means that axe head replacement is recommended.
The Head Becomes Loose or Has a Damaged Eye
The eye is the hole in the axe head where the handle is inserted. If the eye becomes stretched, cracked, or otherwise damaged, it can cause the head to loosen and potentially dislodge from the handle during use – which is extremely dangerous.
Similarly, the wedges used to secure the head may loosen over time from the force of chopping, causing the head to come loose as well. In these cases, attempting to re-wedge and tighten the head is only a temporary fix. Replacing the whole axe head assembly is the proper long-term solution.
The Head is Cracked or Broken
Finally, you’ll need to replace the axe head completely if it develops dangerous cracks or breaks apart into pieces. This type of damage usually results from striking rigid objects with force or excessive wear and tear over many years of hard use.
Attempting to use a cracked or broken axe head puts you at great risk of it completely failing while swinging, which could lead to serious injury. Don’t take that chance – get a new axe head installed right away.
Choosing the Right Replacement Axe Head
With so many different axe head options on the market, you’ll need to carefully consider which replacement head is the right fit for your needs. Here are some key factors to keep in mind.
Axe Head Type
There are various types of axe heads designed for different primary uses:
- Felling axes – For cutting down trees
- Splitting axes/mauls – For splitting logs
- Camping/outdoor axes – For chopping wood and kindling
- Hatchets – For rough cutting and shaping wood
Make sure to choose a new axe head that matches the designed purpose of your existing axe and handle. Using the wrong head type could lead to overstriking, poor performance, and potential safety issues.
Material
Axe heads are typically made from one of three main materials:
- Carbon steel – An affordable high-carbon steel alloy that is very tough but prone to rusting without oiling and proper care.
- Tool steel – A harder, higher quality alloy steel that stays sharper longer but is more expensive. Moderately rust-resistant.
- Stainless steel – A softer, moderately hard steel that provides excellent rust and corrosion resistance but doesn’t hold an edge as well.
The best material choice depends on your budget, expected usage conditions (wet vs dry environments), and whether you prioritize edge sharpness or rust prevention most.
Weight and Length
Axe heads are manufactured in a range of different weights, lengths, and overall dimensions. Using a head that is significantly heavier or lighter than your previous one will throw off the balance and swing dynamics you’re used to.
Whenever possible, try to find a new axe head that closely matches the weight and dimensions of your old one. This will minimize any adjustments you’ll need to make to your chopping technique.
Handle Eye and Hang Angle
The eye is the hole where the handle inserts into the axe head. Different axe types will have eyes and hang angles oriented for either straight-pattern or off-pattern handles. Make sure the new head’s eye size and hang angle match your existing axe handle properly.
Using an incompatible eye size or hang angle will prevent a tight fit between the head and handle. This would make the head prone to loosening and dislodging – a major safety hazard.
Tools and Materials Needed
Before starting your axe head replacement, you’ll need to gather the necessary tools and materials. Here’s a handy list:
Tools:
- Heavy vise or clamp to secure the axe handle
- 2-3 lb sledgehammer or wood mallet
- Hammer wedge, drift punch, or pair of wedging pliers
- Bastard file or coarse grit sandpaper
- Wire brush
- Torch or heat gun (optional for removing stuck heads)
- Penetrating oil like PB Blaster (optional)
Materials:
- New axe head matching your existing handle
- Wooden wedges – hickory or hard maple work best
- Boiled linseed oil or other wood preservative (optional)
Safety Gear:
- Heavy work gloves
- Safety glasses or face shield
- Thick work boots
Having all the required tools on hand will make the axe head replacement go much smoother. Be sure your work area is also clean, uncluttered, and has plenty of lighting as well.
Step-by-Step Guide: How to Replace an Axe Head
With your tools and new axe head ready, you can proceed with removing the old head and installing the new one. Follow these steps carefully:
Step 1: Remove the Old Axe Head
Secure the axe handle horizontally in a heavy vise or clamp, leaving enough space for the head to slide off once loosened. Position the axe so you’ll be striking the head from the side.
Use a hammer wedge, drift punch, or wedging pliers to loosen the existing wooden wedges holding the head in place. Pound these tools against the wedges until you can pull the head free from the handle. You may need to rotate the axe in the vise and strike from multiple angles.
If the head is really stuck, you can try briefly heating it with a torch to expand the metal eye and make it easier to dislodge. Applying some penetrating oil where the head meets the handle can help too.
Be patient and use smooth, controlled striking motions to avoid damaging the handle you want to reuse. This can take some elbow grease but persevere and the head will eventually pop free.
Once it’s off, inspect the handle for cracks or damage and repair or replace it if needed before proceeding.
Step 2: Prep the New Axe Head
Carefully unpackage your new axe head and do a thorough inspection. Look for any burrs, dents, cracks, or other defects that could compromise its integrity and safety. Smooth out small imperfections using a bastard file or sandpaper.
Check that the dimensions of the new head’s eye closely match your axe’s handle diameter. The fit should be tight but not excessive. Gently sand or file down the handle end to fine tune the fit if needed.
Use a wire brush, sandpaper, or other abrasive tool to clean out the eye of the new axe head, removing any debris, coatings, or rust that could prevent a tight fit.
Finally, apply a thin coat of boiled linseed oil or wood preservative to the handle if desired. This will help prevent future cracking and drying.
Step 3: Install and Wedge the New Head
Next, place a hardwood wedge into the eye at the rear of the handle, directly opposite the direction you’ll be striking with your mallet or sledge.
Using a 2-3 lb sledgehammer or hefty wooden mallet, firmly drive the wedge into the eye with smooth, controlled strokes. This will expand the metal eye and lock the head tightly onto the handle.
Rotate the axe 90-180 degrees and install additional wedges by repeating this process. Generally 2-3 wedges per eye is recommended for a solid fit.
Be sure to not over-wedge or you may split the eye or handle. The head should be very snug but you don’t want to distort the metal or wood by wedging too tightly.
Once the wedges are set, use a file, chisel, or saw to trim off any excess wedge material protruding past the eye. This will create a smooth, clean profile.
Step 4: Final Adjustments and Sharpening
After the new axe head is securely wedged on, make any final fitment adjustments if needed:
- Check for gaps between the head and handle all around the eye and re-wedge if there are any slight gaps
- Make sure the hang angle and head orientation look correct for your axe type
- Verify that the head feels solidly attached with no looseness when shaken
Once you’re confident the new head is on properly, there’s one final key step – sharpening!
Even new axe heads don’t come razor sharp out of the box. They have a usable edge but it will cut and split wood much more effectively once sharpened by hand.
Use amill bastard file to carefully put a finer edge on both the primary beveled edge as well as the flat cheeks on either side. Apply even, firm strokes while maintaining the original edge geometry.
For an extra sharp edge, you can then switch to a finer grit sharpening stone or sandpaper. Just be cautious of creating too steep/thin of an edge profile that may chip easily.
Finally, give the blade a quick dressing with a flat oxidized section of the file to remove any burrs and polish the edge.
With the head sharpened, your axe is ready to put through its paces! Be sure to properly maintain the new edge to keep it in peak condition.
Tips for Maintaining Your New Axe Head
To get maximum longevity and performance from your newly replaced axe head, follow these important maintenance tips:
- Keep the axe head clean and lightly oiled, especially after use – This prevents pitting and rust
- Only use the axe for its intended purpose based on the head type – Don’t abuse it
- Periodically touch up the edge with a mill file or stone as it dulls over time
- Inspect frequently for any looseness, cracks, chips, or other damage that needs repair
- Store the axe properly in a cool, dry place out of moisture and dirt
- Consider a vinyl or leather blade guard/sheath to protect and cover the edge
By taking good care of it, your newly installed axe head should provide you with years of reliable service. Don’t hesitate to eventually replace the head again down the road when it eventually becomes worn out.
Supporting Table
Here is a table comparing the key advantages and disadvantages of the three main axe head materials discussed earlier:
| Material | Durability | Edge Retention | Rust Resistance | Cost |
|---|---|---|---|---|
| Carbon Steel | Very High | Very High | Low (requires frequent oiling) | $ |
| Tool Steel | Highest | Highest | Moderate | $$$ |
| Stainless Steel | Moderate | Moderate | Highest | $$ |
As the table shows, carbon steel offers excellent durability and edge retention at a low cost, but it is highly prone to rusting without proper oiling and maintenance. Tool steel provides the absolute highest performance, but at a premium price. And stainless steel gives good overall performance with maximum rust prevention.
FAQs
Can I reuse the old wooden wedges?
It’s generally not recommended to reuse old wedges as they may be compressed or damaged, leading to a poor fit with the new axe head over time. It’s best practice to replace them with new hardwood wedges.
How difficult is it to replace an axe head?
Replacing an axe head requires some degree of skill, specialized tools, and physical effort – especially when removing a stuck-on old head. It’s an intermediate level task that may be too challenging for some novice DIYers. Professional assistance may be needed if you lack experience.
Do I need special tools to replace an axe head?
Yes, you’ll need a few specific tools like a heavy vise or clamp, sledgehammer, drift punch or wedge puller, file, and wooden wedges. Having the right dedicated tools makes the process much easier compared to trying to use makeshift alternatives.
How often should I replace an axe head?
The frequency depends on your rate of usage and how well you maintain the axe head. For occasional homeowner use, a good axe head can last 10-15 years with proper care. Heavy professional use may require replacing the head every 2-5 years. Always inspect regularly for excessive wear.
Can I put a new axe head on an old wooden handle?
Yes, as long as the handle is still in good condition with no cracks or damage, and as long as the new axe head eye is compatible with the size and style of the old handle. The steps shown here work for fitting a new head to an old reusable handle.
Conclusion
Mastering how to replace an axe head is an extremely valuable skill. By carefully following the steps outlined in this guide, you’ve gained the knowledge to breathe new life into a dull, damaged, or loose axe head. With the right replacement head selected and properly installed using wedges, you can get many more years of service from your trusty axe. Regular maintenance is key to maximizing the longevity of your newly replaced axe head. Tackle this cost-saving project with confidence, and enjoy the unbeatable feeling of an razor-sharp, freshly reheaded axe powering through any wooden material in its path.
External Resources Related To Replacing Axe Heads:
- Axe Head Replacement and Safety (Consumer Product Safety Commission) https://www.cpsc.gov/s3fs-public/pdfs/blk_pdf_699.pdf
- How to Replace an Axe Head (Article on SurvivalLife.com) https://survivallife.com/axe-head-replacement/
- Replacing an Axe Head (Video Tutorial from Skillcult) https://www.youtube.com/watch?v=RyNdSmpcRjo
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