Viking Axe Head

I made the printable axe-head as a base body, which I reinforced with 2mm aluminium sheets on both sides. It certainly makes it more sturdy and adds more weight to it, though it's not mandatory. It was designed to fit onto a 1,2m wooden shaft of a local hardware store.

Making process:

first off, print the size rings and take them to the hardware store to check, if it they fit the shaft. The larger ring has the same size as the bottom of the axe-head, the larger one equals the top end. Small size differences are not a problem, it is wood after all, so you can easily shape it to your needs. Then you can start with the actual make:

1. print the full axe-head.
    
2. put a piece of paper onto the side of the print and copy the outlines of it. Carry over the shape onto a piece of sheet metal twice, one for each side of the head. I got my 2mm sheet metal from a local roofer, they do a lot with sheet metal and typically have a scrap container where they put all the metal waste, ask them if you can have a look and grab a piece.
    
3. cut the shape from the sheet metal.
    
4. bend the metal until it perfectly fits the shape of the print. One way of doing so, is with a vice opened by several centimeters. Put the sheet metal on it and carefully hammer at the center of the gap. Don't hit the same spot multiple times, spread the strikes to create an even bend.
    
5. When both metal plates fit perfectly, apply lots of construction adhesive (such as silicone) and glue the plates to the plastic part. Prepare several clamps to create pressure and to hold the parts tightly together while the silicone dries.
    
6. paint the visible plastic surfaces with spray paint that matches the sheet metal color.
    
7. Look up typical viking patterns and carry them over onto your shaft with a soldering iron. The hotter the iron and the slower you move, the darker the lines will be → can take quite long. Drawing the pattern onto the sheft with a pencil beforehand may be a good idea.
    
8. Put the axe-head onto the shaft, drill 4 holes (2 on either side) and fix the head with screws. Then cut away any excess shaft length on the top end.

Done!