Introduction: Splitting Axe Restoration! This Thing Is Cool

By
About: Canadian Craftsman

Welcome to this Instructable, where we embark on a journey to restore an incredible splitting axe known as the Chopper 1. Within these steps, you will discover the art of reviving this powerful tool, bringing it back to its former glory. Restoring the Chopper 1 requires a combination of skill, patience, and dedication to ensure the job is done right. Whether you're a woodworking enthusiast, a DIYer, or just someone keen on understanding the intricacies of tool restoration, this guide is tailored for you. Join us on this hands-on journey as we breathe new life into the Chopper 1, transforming it from a weathered relic into a finely tuned tool, ready to conquer any splitting task. Let's get started!

Supplies

Tools/Materials:

  • Marking Pencil
  • Punch
  • Bench Grinder
  • Belt Sander
  • 60/180/220/400/600 Grit Sand Paper
  • PPE Items
  • Sand Blaster
  • Needle Nose Pliers
  • Metal File
  • Wood Glue
  • Hammer
  • Rust Remover
  • Boiled Linseed Oil
  • Hickory Axe Handle (wedge included)
  • Paint Degreaser
  • Spray-on Primer
  • Spray Paint - Black
  • Paint Marker - White
  • Clear Coat
  • Paper Towel
  • 2 Clevis Pins
  • 2 Cotter Pins

With this comprehensive list of tools and materials, you're well-equipped to successfully restore and assemble your Chopper 1 axe. Remember to follow the steps outlined in the instructable carefully and wear appropriate safety gear while working on your project. Best of luck, and enjoy your revitalized axe!

Step 1: Disassembly

To begin the restoration process, the first step is disassembling the Chopper 1 axe. Follow these steps carefully to dismantle the axe into its individual components.

Materials Needed:

  • Pliers
  • Angle grinder
  • Hammer
  • Punch
  • Safety gear (gloves, safety glasses)
  1. Release the Clips: Using pliers, carefully release the clips from the main spring. Work on one side at a time, ensuring the clip is detached gently. Repeat the process on the other side of the axe.
  2. Grind the Old Pins: Use the angle grinder to grind down the top of the old pin until it is flush with the metal surface. This step might require patience and attention to detail.
  3. Punch out the Old Pins: With the top of the pins ground down, use a hammer and a punch to remove the old pins completely. The levers of the axe will be released once these pins are removed.

Congratulations, the disassembly process is complete! For a visual reference, check out the attached video to see the disassembly steps in action. Now that the Chopper 1 is disassembled, we can move on to the restoration process. Stay tuned for the next steps in this Instructable!

Step 2: Restore Axe Head

Now that the Chopper 1 axe has been disassembled, it's time to restore its former shine and sharpness. Follow these steps for cleaning up the axe head:

Materials Needed:

  • Liquid rust remover
  • Paper towels
  • Sandblaster
  • Belt grinder
  • File
  • Wet sandpaper (various grits)
  • Safety gear (gloves, safety glasses, mask)
  1. Rust Removal Bath: Submerge the disassembled parts, especially the axe head, in a liquid rust remover. Let them soak for at least 24 hours to effectively remove rust and corrosion. This solution will prepare the metal for further cleaning.
  2. Cleaning and Drying: After 24 hours, carefully take the parts out of the rust remover bath. Clean them as best as you can using paper towels. Ensure all rust and residue are removed from the surfaces.
  3. Sandblasting: Use a sandblaster to thoroughly clean the axe head and levers. Sandblasting not only cleans the metal but also provides a consistent matte finish to the levers.
  4. Grinding Away Imperfections: Use a belt grinder to clean up any dings or mushrooming on the axe head. Be meticulous, ensuring the surface is smooth and free from any irregularities.
  5. Sharpening the Axe Edge: Use a file to sharpen the axe edge. Take your time and maintain a consistent angle to achieve a sharp and precise edge.
  6. Final Surface Finishing: Wet sand the axe edge and butt using various grits of sandpaper. This step will refine the surface, leaving it smooth and polished.

There you have it! Your Chopper 1 axe head is now cleaned, sharpened, and ready for paint!

Step 3: Paint Axe Head

With the cleaned and prepared axe head, it's time to give it a fresh, vibrant look. Follow these steps for painting your Chopper 1 axe:

Materials Needed:

  • Painter's tape
  • Primer
  • Black paint (suitable for metal)
  • Paint marker
  • Clear coat spray
  • Safety gear (mask, gloves, goggles)
  • Suitable painting area
  1. Tape Off the Axe Tip and Butt: Use painter's tape to carefully cover the axe tip and butt. This will ensure that these parts remain untouched and provide a clean, professional finish.
  2. Suspend the Axe Head: Hang the axe head in an advantageous position, ensuring it is suspended securely. This will allow easy access to all sides, ensuring even paint coverage.
  3. Apply Primer: Apply two coats of primer to the entire axe head. The primer will enhance paint adhesion and provide a smooth base for the final color coats. Allow each coat to dry thoroughly as per the manufacturer's instructions.
  4. Apply Black Paint: Apply three coats of black paint onto the axe head. Be patient and apply thin, even coats, allowing each coat to dry completely before applying the next. This will ensure a rich, deep color and a professional finish.
  5. Paint Embossed Letters: Using a paint marker, carefully color the embossed letters on the axe head. Take your time and be precise to maintain the legibility of the letters.
  6. Protective Clear Coat: Apply a coat of clear spray to protect the freshly painted surface. The clear coat will add a layer of protection and enhance the overall durability of the paint job.
  7. Final Inspection: Once the clear coat is dry, inspect the axe head thoroughly to ensure an even paint job, sharp letters, and a glossy finish.

Your Chopper 1 axe is now beautifully painted, preserving its legacy while giving it a new lease of life. With the restoration and painting process complete, your Chopper 1 axe is ready for a handle!

Step 4: Install Axe Handle

With a newly selected handle from the hardware store, you're ready to retrofit it to your axe head for a perfect fit. Follow these steps for a seamless axe handle installation:

Materials Needed:

  • New axe handle
  • Pencil
  • Sandpaper
  • Belt sander
  • Axe head
  • Wood glue
  • Wooden wedge
  • Band saw
  • Safety gear (gloves, safety glasses)
  1. Remove Protective Coating: Use sandpaper to remove the stock protective coating on the newly purchased axe handle. This step is crucial to eliminate slipperiness and ensure a firm grip.
  2. Trace Axe Eye Shape: Place the axe head over the new handle. Trace the general shape of the axe eye onto the handle. This outline will guide you on how much material needs to be removed for a proper fit.
  3. Remove Excess Material: Use a belt sander to remove excess material from the axe handle. Periodically check the fit by placing the axe head onto the handle to ensure you are removing just enough material for a snug fit. Be cautious and remove material slowly to avoid overdoing it.
  4. Final Sanding: Give the handle a final sanding to achieve a smooth, comfortable grip. Pay attention to details and ensure the handle is free from any rough spots or splinters.
  5. Insert the Handle: Insert the new handle into the axe head. Once the axe head has seated slightly, gently tap the butt of the handle onto a concrete surface. Gravity and momentum will help seat the head securely onto the handle.
  6. Insert the Wedge: With the axe head properly seated, insert the wooden wedge into the slot. Apply wood glue to the wedge before placing it into the slot. Hammer the wedge down into position until it cannot go any further. This ensures a tight and secure fit.
  7. Trim Excess Material: Use a band saw to trim any excess material protruding from the slot after inserting the wedge. Be precise and ensure the surface is close to flush.
  8. Final Sanding: Perform a final sanding of the top of the handle to achieve a proper finish.

Your Chopper 1 axe handle is now securely installed, providing a sturdy and reliable grip for precise splitting tasks. Ready for final assembly!

Step 5: Final Assembly

With your Chopper 1 axe head restored, painted, and the handle securely installed, it's time for the final assembly. Follow these steps to complete your project:

Materials Needed:

  • Pliers
  • Clevis pin
  • Cotter pin
  • Boiled linseed oil
  • Cloth or brush for oil application
  1. Install Springs onto the Levers: Using pliers, carefully install the new springs onto the levers. Ensure they are attached securely, providing the necessary tension for smooth operation.
  2. Position the Levers: Slide the levers into their proper position on the axe head. Take your time to align them correctly, ensuring they fit snugly.
  3. Insert Clevis Pin and Cotter Pin: Once the levers are in the proper position, insert the new clevis pin through the designated holes. Secure the pin in place by inserting the cotter pin through the hole at the end of the clevis pin. This ensures the levers are securely attached to the axe head.
  4. Apply Boiled Linseed Oil: To protect and enhance the longevity of your axe handle, apply boiled linseed oil. Use a cloth or brush to evenly coat the entire handle with the oil. Let it absorb for a few hours, or as per the manufacturer's instructions, giving your handle a beautiful, natural finish and added durability.
  5. Final Inspection: Carefully inspect the entire axe to make sure all parts are securely assembled and functioning correctly. Double-check the tightness of the clevis pin and cotter pin, ensuring they are properly secured.
  6. Split Wood!

Congratulations! Your Chopper 1 axe is now fully restored, assembled, and ready for action. With its revitalized appearance and enhanced performance, this iconic tool is prepared to tackle any splitting task you throw its way. Enjoy your restored Chopper 1 axe, and may it serve you well in all your woodworking adventures!

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