How to Make an Ax That Gives You Double Effect

  • By: Monica Shulz

Looking for an ax with double performance and double value for money? You can make one right at home without breaking a sweat or the bank. Check out these simple DIY steps for an ax with double effect and double hit.

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Dislodge the Old AX

Find two sets of old axes that you no longer deem fit for the tough job ahead. Clamp them firmly with the ax head up one by one. Place a blacksmith’s hammer on the wooden ax pin inside the head and using an engineer’s hammer, gently hit the blacksmith’s hammer until the pin dislodges completely.

Alternatively, you can just dislodge the pin directly using a hammer without clamping. Once you have your two metal ax heads, proceed to prepare them for the real task.

Design the AX Heads

Start by thoroughly sand grinding one of the heads to smoothen any rough patches and get rid of the chipped paint. The ax head, not grinded will be used to produce the needed modification parts.

Place the grinded ax head on its counterpart lying on its side. Make sure it cuts through the center of the underlying ax head. Hold it steadily in position and make markings along and around the shape of the upright ax head using a steelwriter marker pen.

Slice the AX Head

Firmly clamp the marked ax head and start angle grinding along the markings. Slice off the two sides of the ax head leaving the hollow ax head section intact. The two sliced-off metal pieces should look identical if you made the markings precisely.

After the metal pieces cool down, fine-tune (edge smoothing) them by running them across a belt sander machine.

Assemble the Metal Pieces

Grab the other ax head that wasn’t grinded, lay it on its front surface, and start prepping your design assembly. Start by placing one of the identical small metal pieces on the underlying whole ax head. In this step, correct positioning is key. Target the centermost placement.

If you are certain your positioning is well aligned, put on your welding gear (gloves and welding helmet) and arc weld the small metal piece perpendicularly to the underlying piece. You can use your T square ruler to confirm the right angle placement.

If the angle fits, proceed to the next metal piece. Arc weld it on the opposite surface of the original ax head. Make sure the placement aligns with the other small ax metal piece.

Finish the Assembly

The entire finishing process involves sand grinding all the faces of the new metal head to smoothen it finely. The new ax head resembles a crisscrossing head with eight identical faces. Once it cools down, clamp it firmly and start sharpening every single edge.

After sharpening, the newly assembled ax head is sparkling clean and ready to cut through even the toughest of blocks. Remember, you don’t need to make any adjustments to the hollow section of the ax head.

Reattach the Wooden Pin

Use the same wooden pin you had earlier dislodged to reattach the newly formulated 8-faced ax head. You can reinforce your attachment using a simple soft plastic mallet hammer. Next, use a handheld wood cutting machine to slice off a small wooden chip (about one-inch-long) to be used for ax pin reinforcement.

Smear white wood glue on both surfaces of the wooden chip and insert it right at the center of the ax pinhead. Drive the chip into the pin using your plastic hammer and chop off the excess wooden chip using a mini handsaw.

With the complete attachment, sand off the wooden pin before applying a brown wood varnish or stain to boost longevity. Finish by drying off the varnish with a soft cloth.

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The end product

This is finally it. The beastly woodcutter. With additional slicing edges, comes extra strength, agility, and chopping power. With just a single hit, you get twice or thrice the effect.


If you are looking for a homemade solution to save time chopping those tough wood blocks, this DIY ax is the way to go. Made from recyclable materials, you are bound to enjoy every inch of your chopping experience. Ensure you make precise cuts in the design of the ax.

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Photo by DIY projects / CC BY 3.0