After participating in this thread and seeing the condition of some of my old tools I decided to clean a few up before putting them away again. The 2 broad axes in post #9 without handles were in very rough shape. I don't even remember where I got them. The rust and pitting was so bad I photographed them with one side sanded down to show the difference.
The flat side is the most important because that is always the leading edge of the blade. I need to get all the pock marks out of that surface or they will deform the cutting edge. I didn't bother derusting them as I knew I had extensive grinding to do. My goal is to get them close to complete only. Eventually I'll hand file them before use.
A broad ax starts out as a flat piece of steel the blacksmith cuts to a butterfly shape then welds a 1" - 1 1/2" strip of tool steel to one end. He then folds it over near the middle to form the handle pocket and then forges the top layer into the bottom section merging the 2 ends of the flat steel together for the blade. You will see these 2 layers in some of the photos.
The broad ax on the left revealed the origin of the ax after some cleaning. It was made in Sweden which surprised me because this pattern is known in North America as a Canadian Pattern with the peak in the centre of the blade. Some one at some time also squared off one end of the blade, I'm not sure why.
I started sanding with a 120 grit disc on my 7” angle grinder but moved to a 40 grit before long. I’m not going to worry about grinding out the deep pock holes all the way out, just the ones around the cutting edge, then this baby will split wood again. As far as the overall surface goes I’m happy with what the right side looks like now and will do the left side to match.
This one has worse pitting than the Swede Ax. I’ve done one side ahead of the other on this one too.
On the back corner I’ve found a spot where the 2 layers have separated and rust has entered. After gringing into the area I found the rust is about 1” deep from the corner. Since I can’t leave well enough alone I’ll grind it out and weld in the top surface again.
I made a block of ice in the freezer and laid the tool steel cutting edge in the ice, then welded beads across the ground out area cooling and grinding until I got the area built up with weld, then ground it down flat. It looks all good now.
I’m going to sandblast them and do a black oxide treatment next. That should be about a week away.