The goal of this project was to make a functional hammer out of free materials to practice both my metal and wood working skills. The result of this project is a functionalist hammer which utilizes multiple materials and many manufacturing techniques.
The Head started out as a piece of low carbon steel round stock which was sleeved in steel tubing; to secure the two pieces together, two holes were drilled for rivets and a third was made to fit the handle.
The rivets were made using steel rod which was dimpled on each end and heated to make the process easier.
Once the head was assembled, I began hammering every part of the outer surface with a ball peen hammer to give it stronger and more dynamic appearance.
The final operation done to the head was drilling and tapping a hole for the attachment of a brass face plate. Brass is a soft and heavy material which is ideal for the gentle persuasion of things best left unmarred.
The handle was sanded to shape until a comfortable oval shape was achieved that tapers to fit the hammer head. The head fitment was made right by trial an error; removing material form the handle until the head sat snuggly at the base with no gaps and properly oriented in line with the head. A notch is cut in the inserted portion to facilitate the use of wedge.
The use of a wooden wedge follow by metal step wedge 90 degrees out of phase ensures that the handle is firmly attached.
Finally the Brass Piece was cut to size and a counterbored hole is drilled through the center. The Brass is square because it is easier to pin point the force on an edge or corner. Conveniently this also allows the hammer to stand vertically (or horizontally) which increases one handed ease of use.