here's the basics provided you can already forge-weld
this is as best as I can describe without photos or video,I'm sure someone's youtubed it.
thin and flat the ends drawing outward while keeping the center full thickness. It should look like a bowtie or hourglass before you fold and weld the body of the axe. Weld the body starting at the edge of were you want the eye moving toward the cutting edge, being sure to leave enough un-welded material at the fold to drift open the eye (provided you are not using an eye mandrel to begin with) Do not work or thin the eye as you open it back up you need the mass there when done to backup the taper of the blade for a good strike.
If you are using a bit scarf and fit it before welding as you will want to insert it in between the two layers when you get to the last 1/2in or so of your body weld making sure to heat and flux all pieces evenly, if not ignore this line.
Or if you are just looking at doing simple mouse hawks and throwing axes; take a strip and just roll the eye at one end on a mandrel not even bothering to weld it (kind of like the socket on a shingle cutter) and form your edge. These don't split at all because there's no real body or taper but with 4in or so from edge to eye they make good light choppers and throwers. You just cant cut deep because they hit the eye the same way a knife stab would be stopped at the base of the blade when it hit the guard.
I am by no means an expert and its been about 5 years since I last made an axe, so my instructions are rudimentary at best. I remember doing a axe with a bit when first learning to forge weld 15yrs ago with little more than this, it sucked.
Find a youtube video or if there's an ABANA affiliate near you check them out a member may be willing to help.
Leaf springs are usually in the same family as 5100 and 6100 series low chromium spring steels and tend to make good durable blades.
« Last Edit: December 15, 2014, 02:30:04 PM by Noa Isumi »
I used to be a lot of things, and someday will again.
But for now I'm just a lost jack of trades with neither mastery nor home. ~NoaIsumi