I've had this Michigan-pattern Kelly True Temper "A39" felling axe head knocking around my shop for a while now. I think it weighs 3.5 lbs. Cannot recall where I got it. So, since my body is beat up and needs a rest from construction, I figured I'd make handle and sheath for it.
A couple years ago, I bought this chunk of curly western maple. Good looking, but not very strong. A bad choice for an axe handle to be sure. Let's use it!
Last week I sold my big bandsaw to the former State Geologist of Alaska, so I had to dig out the jigsaw. The dado stack helped me hog out the bulk of the material remaining.
The shape of the handle came from the classic old railroad template for a "poll axe", though I modified some of the dimensions.
My rough blank was 36" long x 2-5/8" wide x 1-3/4 thick. Someone else drew this diagram.
I make the wedge from an offcut of the same maple board.
Maple wedge with linseed oil goes in perfectly. I start with a flared wedge, give it a couple taps, then trim it down to fit the eye.
A proper fit.
A quick trip to Tandy Leather to get some rivets, snaps, and leather. I cut out the 4 simple shapes and knocked them together. I sanded and burnished the edges with water, then wax. Waxed the sheath, shined up the head, and waxed it, too. A couple coats of Danish oil for the handle, wet sanded with 600 grit.
Not fancy, but its done. Started at noon, done at 7pm including emails and a trip to town. The axe will ship out to Texas in the morning.
This axe is for the wall, not the woods.
Shipping size is 31-5/8" x 8-1/4" with the sheath on.
Actual size is 31-1/2" x 7-5/8" with no sheath.
Three layers of 1" rigid foam made up the packaging.
Less than $50 to ship from Alaska to Texas with FedEx.