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How To Replace An Axe Handle

Jess

September 13, 2023

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Whether used for chopping wood to start a fire or some other purpose, anyone who has used an axe for long enough will tell you, it will, like anything else, begin to show signs of wear and tear. Typically, this will initially present itself in the axe handle, rather than the axe head. Eventually, this may lead to the old handle becoming a broken handle, at which point you may think it’s time for a new axe. However, rather than spending the extra expense on an entirely new axe, replacing the axe handle will be cheaper. Additionally, if the old axe head is still good it will save you time sharpening up a new one, whilst avoiding unnecessary waste. If you’re wondering how to replace an axe handle, don’t worry, we’ve got you covered.

Table of Contents

• The New Axe Handle
• Homemade vs Store Bought
• What Type Of Handle Should You Go For?
  • Size
  • Shape
• How Grain Type Is Important
• Does The Type Of Wood Matter?
• Varnished Vs Unvarnished Axe Handles
• Removing The Old Axe Handle
  • What Tools Are Needed To Remove An Old Axe Handle
  • What You Shouldn’t Do
  • How To Remove The Handle From Your Axe Head
• Installing The Axe Head On Your New Handle
  • What Tools Are Needed To Install A New Axe Handle
  • How To Install An Axe Handle
• Is a New Axe Handle Worth it?
• FAQ

The New Axe Handle

Once you’ve resolved to get a replacement handle for your axe, there are a few things that you should consider. For example whether to go the do it yourself route or buy one from the store or what kind of wooden handles are best, amongst other factors, are all things that you should bear in mind.

Homemade vs Store Bought

When considering whether to buy a new axe handle or make your own, the decision will likely come down to how adept you are at woodworking. However, other factors may also influence your decision.

One of the biggest factors is time, this is because making your own axe handle will take a lot of it. Before you can even begin designing and carving the handle, you will have to assemble the necessary tools and source wood that is appropriate for the job. Whilst you will still need to weigh up your options at the store, once you’ve settled on a design, you can just buy it. 

On the other hand, though, designing your own handle will likely work out cheaper due to only having to buy raw materials. Additionally, if you are adept at woodworking, you could design a handle that is more tailored to your own specifications.

What Type Of Handle Should You Go For?

When buying or making the handle for your axe, the type of handle you go for is an important factor to consider. Whilst deciding, it is important to consider the type of axe that you’re needing the handle for. Typically, there are universal standards for store-bought axes and handles. However, both the size and shape can vary. 

Size

The sizes of different handles are typically quite consistent depending on the purpose of the axe they are designed for. 

For the most part, longer handles are used on axes intended for larger cutting tasks such as felling trees. This is because a larger handle will help to provide more leverage when swinging.

However, smaller handles may be best suited for axes used for lighter work such as limbing. Meanwhile, the smallest handles will be used for axes like hatchets which provide more precision.

Shape

Whilst axe handle sizes are typically more standardised, the shape of the handle can vary somewhat. This is because the type of wooden handle that is best for each person can vary on a case by case basis. 

Whether you prefer a straight or curved handle will be something you’ll likely discover through trial and error. However, often splitting maul handles or those on a double bit axe will be straight, whilst carving axes will have curved and felling axes can go either way. 

How Grain Type Is Important

When deciding on a handle for your axe, the grain of the wood is something that should be paid close attention to. This is because the grain can give a surprisingly accurate idea of how durable the handle will be.

Ideally, when picking out an axe handle or piece of wood to make one from, you’ll want the grain to be straight with rings that run parallel to the bit. If, however, you can’t find one that looks exactly like that, then you should seek out the grain that is straight down at the very least. 

The reason for this is because the straight-grained wood will have been cut from trees that have grown straight. These will be stronger as the tree will not be twisted and gnarled, making it more stable. As a result, the handles made from these trees will be more durable. 

As such, when buying a handle or wood to make your own, you should avoid sloping and diagonal grains. Additionally, if the wood has any pinholes or knots, it should also be avoided as these will further weaken the handle.

Some manufacturers will fire-harden or stain their handles. These types should also be avoided since you will not be able to accurately gauge the quality of the grain on these handles.

You may have to shop around a little to find a good quality handle with a straight grain. However, this will definitely be worth it as the handle will last much longer.

Does The Type Of Wood Matter?

A subject of much debate is whether or not the two most common types of axe handle material actually have any significant differences. Popular wisdom will often assert that handles made from hickory wood, a type of sapwood will be better than heartwood options. 

This is because the former is often considered to be more durable than the latter. However, how true this assertion is, is up for debate with studies finding that there is little significant difference between them in terms of durability. 

In fact, the main difference between them might come down to aesthetics more than reliability and durability. This is because hickory sapwood is a lighter colour whilst heartwood is a dark reddish-brown colour. 

Ultimately, which type you go for however will be less important than the grain of the wood. As even if sapwood is better, that is irrelevant if you pick a handle with a poor quality grain.

Varnished Vs Unvarnished Axe Handles

When browsing different axe handle options you may notice that unvarnished handles are typically more expensive than vanished ones. This may seem counterintuitive but there are actually quite good reasons for this.

A varnish or lacquer will protect a handle in transit, ensuring that any scuffs, marks or any other types of cosmetic damage don’t take place. This is because an unvarnished axe handle that is in the same physical condition as a varnished one may look worse after this period of transit. As a result, people may be less likely to buy them. As such the varnished ones are a better value choice for the axe handle producers since less stock will be rejected.

However, varnish handles are prone to a few downsides that unvarnished ones won’t suffer from. Contrary to popular belief, the slicker, varnished handles are more likely to cause splinters due to the increased friction generated when swinging. Additionally, there are concerns that the lacquer may be potentially toxic, as such you may not want to make prolonged skin contact.

Many people also don’t like the way that varnished handles look. Obviously, this is a purely subjective point but many purists and traditionalists prefer the natural and earthy look that oiling provides.

If you can only find or afford unvarnished handles, however, this isn’t the end of the world. The reason for this is that the factory varnish can be easily and quickly scraped away with the right tools. Typically a cabinet scraper should be able to accomplish this task. If you elect to do this or have an unvarnished axe handle though, you should make sure that you oil it after hanging your axe head to it.

Removing The Old Axe Handle

Once you have decided on your new axe handle, the next stage is to remove the old one. Unless of course you currently just have an axe head. In this case, all you need to know is the installation part of how to change an axe handle meaning you can skip this part.

If not, the process of removing the old handle is quite simple and does not require any specialised equipment.

What Tools Are Needed To Remove An Old Axe Handle

The tools needed to remove an old axe handle are as follows:

• Vice
• Drill
• Handsaw
• Cold Chisel, Wood Chisel or Slotted Screwdriver
• Hammer
• A Punching Implement: Could be something like a block of wood
• A Screw And Set Of Pliers

How these tools will be used will become clearer below.

What You Shouldn’t Do

Occasionally, you may hear that a simple way to get rid of an old handle is to throw your axe in the fire and let the handle burn away. Whilst this will get rid of the handle from your axe head, it is something that is strongly recommended against doing. 

This is because, fundamentally, doing so is highly likely to damage the axe head. Most likely by warping it somewhat. Additionally, depending on the material and treatments used in creating the handle, burning it may be dangerous. This is because burning the wood may release toxic fumes.

How To Remove The Handle From Your Axe Head

The process of removing an old handle from your axe is actually a surprisingly simple process. Once you’ve assembled the tools mentioned above and prepped your work area, you’ll be ready to get started.

To remove the handle of an axe, adhere to the following instructions:

1. Firmly secure your axe in the vice, angled so the handle is facing upwards. Doing this will help make removing the main bulk of your old handle easier. To prevent any scratching from occurring to the axe head, place a rag around it before putting it in the vice. This is only necessary if there are no wooden cheeks in the jaw of the vice already.
2. Cut the old handle away from the axe with a saw. When doing so try to get as close to the head as possible.
3. Once the bulk of the handle is severed, remove the axe from the vice. Then flip it so the topside of the head is facing upwards and tighten it back in the vice.

The next step depends on if you have a loose handle or one that is firmly secure. If it is loose then do the following:

1. Without removing the wedge, take a piece of wood smaller than the eye of the axe head and place it on top. 
2. Then hammer this block of wood until the remainder of the old handle falls away.

However, if the handle is not loose or the other method didn’t work, then you’ll have to remove the wedge. To so, follow the subsequent steps:

1. When removing the wedge, you should first assess whether you’re dealing with a wooden wedge or a metal wedge. The methods for extracting these can vary. As such identifying whether you’re dealing with a wooden wedge or metal wedge is important. 

• Metal wedges or a steel wedge as they’re also known can be removed by drilling a small hole into the centre. Following this, screw in a screw until it is firmly secure but still protruding. Finally, use pliers to pull the steel wedge out by the screw.
• Whilst the former option may work for a wooden wedge, there is a safer way. This is done because if the wedge splits then the job becomes more difficult. As such for a wooden wedge it is best to gently drill a few holes into the wood wedge and then pry it out carefully with a screwdriver or cold chisel.

2. Following this, there may be a second wedge. Unfortunately, there’s no real technique for this part aside from forcing it out with a chisel or pliers.
3. Once you’ve removed the wedge or wedges, take a piece of wood smaller than the eye of the axe head and place it on top of the now exposed handle. 
4. Then hammer this block of wood until the remainder of the old handle falls away.

Installing The Axe Head On Your New Handle

After removing the old handle it is now finally time to install the new one. Like removing the handle, the process to add a new one is simple and doesn’t really require any specialised equipment. Simple tools will be sufficient.

What Tools Are Needed To Install A New Axe Handle

The tools needed to install a new handle to your axe include the following:

• Axe Handle
• Pencil
• Handsaw
• Coping Saw
• Sharp Knife
• Rasp
• Wooden Wedge
• Boiled Linseed Oil
• Mallet/Hammer

How these tools will be used will become clearer below.

How To Install An Axe Handle

Like removing an old axe handle, adding a new one to your axe is surprisingly easy and simple to accomplish. Once you’ve got the tools and supplies required and the old handle has been removed, you’ll be ready to begin.

A brief note before hanging the axe is that you should clean up the inside and outside of the axe head. Doing so before installing the handle will make things much easier to do.

1. Lay the new handle flat and rest the axe head atop it. When doing so, align the handle’s shoulder with the bottom of the axe head’s eye. 
2. Mark off where the top of the eye rests on your handle. Following this, cut off the top of the handle at the point marked. Doing so will make the process of installing the new axe head much simpler. 
3. Use your saw to deepen the wedge kerf. Ideally, the depth you want is roughly two thirds that of the eye of your axe head.
4. If the new handle has a fawn’s foot then removing an inch from the tip will help provide a level surface. This is useful later for pounding.
5. Push the new handle into the eye as far as it will go. When doing so, ensure that the handle is centred in the eye whilst being perpendicular to the top of the axe. Once in position ensure that the handle is secure enough for the head to not fall off when flipped upside down.
6. Whilst holding the axe upside down, tap the end of the handle with your hammer. Whilst odd, this will drive the handle into the head so long as step five was completed successfully. When doing so, hold the axe just above the ground and ensure you don’t crack the new handle by striking too hard.
7. If having problems with properly securing the new handle, then remove the head and inspect it. If there are any areas of dirt or rust then rasping them away will help. Keep doing this until the axe head will fit the new handle but with some resistance.
8. Once the handle is secure, use a coping saw to cut the part of it protruding from the top of the eye. Whether you cut it flush with the axe or a quarter-inch higher is up to your discretion.
9. Next is to hammer in the new wedge. If your new handle didn’t come with one, you’ll have to make your own. 

• Fortunately, this can be done with a bit of hardwood such as poplar cut down to size with your knife.
• Once cut to size, coat it with boiled linseed oil.

Use a hammer to drive your wedge into the kerf. Doing this will firmly secure the head of your axe to the new handle. Whilst doing so, however, refrain from hammering it in too deep or the wedge may split. 

10. The wedge will likely protrude somewhat from the handle of your axe. If this is the case, then simply use a coping saw to make it flush with the handle.
11. To be extra certain you may then also want to drive a metal wedge over the wooden one. However, if the prior steps have been followed correctly, then this isn’t compulsory. Instead, it is merely a good way of ensuring that the handle is sturdy.
12. Once the handle is securely in place, give the entire thing a good coating of boiled linseed oil. Then once any excess residue has been wiped away, your axe is once again ready to use.

Is a New Axe Handle Worth it?

Now you know how simple it is to install a new axe handle, you’ll likely never buy a new axe again. Well, at least as long as the head is still good. As such, whilst a new handle should last a while it’s a wise idea to have a few spares, just to save you the time going to the store in future.

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