How to fit a new handle to an old hammer or axe

Step by step

1. 1

   Step 1: Get the old handle out

   Saw the old handle off just under the head. Drill a few holes through what's left in the eye, then drive it out from the narrow side with a punch.

2. 2

   Step 2: Clean the eye

   Wire brush the rust out of the eye so the new handle sits on clean steel. Clean and derust the head while you're at it.

3. 3

   Step 3: Shape the new handle to fit

   Hold the head over the top of the handle and mark the eye shape. Rasp a little at a time until the head goes on about two thirds of the way by hand. A tight, even fit matters more than speed.

4. 4

   Step 4: Drive the head on

   Hold the handle upright and strike the bottom of the handle with a mallet. The head's inertia pulls it down onto the handle. Keep going until the head is fully seated.

5. 5

   Step 5: Wedge it

   Saw off the handle top so a few millimetres stick out. Drive the hardwood wedge into the slot across the long axis of the eye with a drop of PVA, trim it flush, then drive a steel wedge in diagonally.

6. 6

   Step 6: Oil the handle

   Rub boiled linseed oil into the handle and let it soak in. Do a few coats over a couple of days. Don't varnish a handle: oil grips better and won't blister your hands.