Axe Making
with the
Ancient Forges
Group courses (between 3 and 6 people) are run out in the open using archaeologically reproduced Iron Age and Roman/Saxon forges, basically holes in the clay with charcoal and bellows! The whole process of making the axe is done using hand tools but there is no reason why you can’t turn out very good tools with this set up, despite the lack of mod-cons. Afterall, if it weren't possible we would never have progressed to where we are today!

These forges require a little more effort on the part of the operators than a modern forge, because when not actually forging you are likely to be pumping the bellows for your comrades. Time constraints are a little tighter due to the heat treating, but I still let YOU decide what you make, the only restriction is the metal we start with.

We start with a piece of virgin tool steel of the appropriate size (normally about 1" square by 4" long) and a bit of ash (from my woods of course) and we gradually turn them into a small hatchet or adze. I used to provide small hammer heads for people to reforge, but the virgin steel allows for much more freedom in design.
Click on the images below for a better idea of what you could do. I've arranged them to show the whole process from forging through to carving and fitting a handle.  The second gallery is the rogues gallery, showing you a selection of former students and their finely crafted axes and adze!
Here are some of the axes and adze produced in the Iron Age forges. Most of the pictures includes the  axe that I made alongside the group.
booking and course enquiry
Examlpes of students' work
It takes a little while to get the lump of metal hot, but as soon as it is work can beginStart by punchin a slug of steel from the middle of the bar. This can be done solo, but a helper is sometimes easierA drift (tapered bar) is driven through the slot to open up the corect shaped/sized eye. Easiest if there is a striker to helpOf course, REAL women swing the sledge hammer in one hand!Next the blade of the axe or adze is worked down using a sledge hammerthe finer shaping and final drawing out of the blade is done by hand.The rough shaped head is then normalised to relieve stress and refine the grain structure.  After this the cutting edge is tidied up with a fileAny irregularities in shape are filed off and the head severed from the bar.The axe heads are quenched in oil or tallow .after hardening the blades are tempered to hold an edgeA slection of finished axe and adze heads. The end of Day 1 (mine at the top)Day 2. The handles are carved from a piece of sesoned, cleft ash from my woods. Starting with axes...the shape is further refined with drawknives, rasps and spokeshaves.Once the shaft is mostly shaped, it is roughly fitted to the head and the alignment can be tweaked as we go.Finally the axe is sharpened ready for use!Voila! Fiished axes and adze.
October 2007. My first axe making course. 2007, some fine axes and adzeAxe making group in March 2008march 2008 axes. My axe is second up and is the one that goes with me to showsApril 2008 a private group booking. These guys did especially well considering the weather that we had!April 2008 axes, mine seems to have been missed outApril 2009, Private group (Rob's stag weekend!)Rob and Co only wanted forgework, so axe/adze heads on one day and knife blades on the second.2010 axe making class (the final member ran off early, so is in a seperate shot)the final member of 2010 :-)2010 axes. Mine is at the centrethe missing axe