WELDING SLAG CHIPPING HAMMER FROM AN OLD FILE.

I've been using this principle for many years because of it's simplicity and efficiency over the commercially bought specimens which were as a rule too bulky and heavy to my liking. The glass like hardness of the file provides an ability to easily crack the slag without blunting too soon.
Good welding usually does not require excessive hammering or chopping. The slimness of this tool allows access to small spots with more precision and reduce the need for unnecessary force that could leave chopping marks on your work piece.
In conclusion, it is very easy to make and cheap as dirt.
Attachment 29274

This file is approximately 6mm thick and about 2cm wide and marked out to rough proportions like on the picture.

Attachment 29275

It is then cut up, taking care to not heat up he metal too much so that the hardness of the file is retained.

Attachment 29276


A handy piece of 25 x 12 rectangular tube lying around is cut to approximately 300mm and a slot is measured out and cut to receive the hammer head. I prefer rectangular or square material that does not tend to slip and turn in your hand. In this case the dimensions of the tube makes it unnecessary to add a grip to the handle. Flat bar also works just fine.

Attachment 29277Attachment 29278


By now, the chopping surfaces of the head are already ground... easier to do before welding.

Attachment 29279

Not too severely welded. Remember heat messes up the temper.



Attachment 29280Attachment 29281
Ready for use

Attachment 29282


And a bit of paint for pride!

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nice idea, well thought out for as simple as it is, it quite improves on the commercial versions. I like it!

Quote:

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Originally Posted by Raytonian

...snip... The glass like hardness of the file provides an ability to easily crack the slag without blunting too soon.....

...snip.... It is then cut up, taking care to not heat up he metal too much so that the hardness of the file is retained.

... snip... Remember heat messes up the temper.

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Although the idea of using a file is a good one, three things caught my eye with this project.

1. A file, as purchased, should not be used as a hammer, its "glass like" hardness is prone to breaking what struck.

2. Subjecting the file to a bit of heat while cutting and welding is actually tempering the steel, probably why your chipping hammer has not broken during use.

3. As in number 2, tempering is only messed up if the end product does not have the properties you had hoped for. By sacrificing a bit of the files hardness, you gain a lot of required toughness with a bit of heat, as long as you do not over do it. When a file is made, the body it left as hard as possible, while the tang is tempered to make it tougher. Heating the body some while cutting and welding, may very well be why your file hammers are working.

This web page shows a chart of temperatures for tempering steel for various tools. Very handy to have around if you are making tools using steel from other tools. If you look closely the file is not listed on the chart. http://cedarriverforge.com/Photo-ind...r%20charts.jpg