This involved a lot of rust removal initially. I started with a diamond abrasive sanding sponge to get the worst of it, then moved to a wire brush on a flex shaft tool as well as an 80 grit radial bristle brush on my Foredom bench lathe.
After this I set about refinishing the faces of the hammer. They were deeply pitted which is not a good thing for the sort of metalwork I do. Any mark or pit on the surface of the hammer face will get imprinted on the metal I'm forming with it over and over again. Initially I tried just working with my coarsest diamond grit sanding sponge, but that wasn't getting me anywhere significant. The hammer face was well hardened and deeply pitted. So I did break out the 4.5 inch angle grinder and went to town on it, being careful not to overheat the metal while also keeping the proper head shape. With the broken corner on the boxing face there was no real repair possible. I opted to just blend that back a bit further, softening the edge, so if I do use that side I can hopefully avoid that corner making unsightly hammer marks from a ragged edge hitting. Then I finished up the hammer faces with sanding sponges which conform nicely to curves and brought it down to a suitably smooth finish.
There was still some rust in crevices and the hole for the handle so I decided to try the vinegar trick which I learned reading the BB submissions of others! That seemed to work. Finally I applied a thin coat of some old, rancid canola oil I have. Copying M Broussard's trick I then heated it up with a fuzzy torch until it just started to smoke to set it as a better finish.
Finally, once the handle was made I got it all mounted and restored to working order. In cleaning this up I could see this is an old hammer that has seen a lot of use. I have to wonder what its history really is. What stories could it tell? I doubt I'll actually use it much as it's designed for a style of raising I don't do, not to mention larger scale pieces than I generally do as well. Still this was somebody's workhorse hammer at one point in the past. Hopefully I've revived it well enough that it can be for someone else in the future after me.
Mike Barkley approved this submission.
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