DIY Walking Axe

what test is it failing?

The business end on the pick looks a bit thin and pointy, that little thorn. Also, I’ve been looking for confirmation on the adze. So many have a square adze, might be preferable for single-chop efficiency?

The 30* angle might be a little acute:

Check out Stanley’s Helios Ti axe. Love the bottle opener.

PS on the adze bevel, on the (beautiful) CAD drawing, just noticed it is a single straight across bevel leaving the shoulders squared, not sure if that’s what you wanted.

The splintery carbon may like a ferrule cap containing it, if the connector has beef for that. Possibly a separate ring glued over instead?? Like:

Here is a picture of the test it fails. Can only take about half the load.

Regarding the other comments.

The chamfer is just straight across because it will be easier for me to manufacture that way. I can set up for the angles, but just wanted to minimize the machine time.
I think the sharp angle will be useful considering how light the head will be – not sure if 30* or 45* would even really make a difference.
I had the shaft connection designed with the cap, but then couldn't find material with a wall thickness large enough to cover the OD and ID – unless of course I bored a hole in a solid bar (no thanks), and then I still have to put a 0.035" groove in it. You can notice the size difference between the O.D.'s in the model if you look closely. I was just going to cover it with some epoxy, but a ring would be nicer.
Steve

Guessing the pick deforms, maybe have the point of a tooth right at 25 mm?

Uncheating – that is still wont help pass the test but might be good in real life: If you know you will be using it right handed on ice, and placing it to your right, the axis of the head could be a few degrees off the axis of the shaft. The pick slot could be angled. More appropriate for an ice tool, got to consider a possible resulting decrease in self-arrest effectiveness.

Back from a week long trip.

Steven, tell me the ID and I will whip you up a carbon tube. The ID should be the critical dimension with the parts going into the carbon tube.
Also give me the OD just for reference and the length you want so I can design the best tube to meet the strength criteria.

Kevin !!

Ahhh, there you are Kevin ;)…yes, I have decided to go the carbon/ti route.

I'm assuming you make carbon shafts at work? or something like that?
First off, how much is this going to cost to have you "whip up" a custom one? This was supposed to be a DIY project, not a full production product :)
Secondly, what type of capabilities do you have? Can you make any shape out of carbon? Or just round shafts? Can you make a shaft with a bend in it? How about a oval tube with a bend in it?
The carbon shaft I have been looking at getting (Macqc.com) has in ID of .75" and and OD of .82". However, if you can make any size, I will change that.
In one of your first posts on this thread you mentioned the carbon being 20% stronger. The numbers passed on to me from macqc show the carbon being several times stronger then aluminum (ie. 295 ksi tensile)…can you achieve these types of numbers?
In my design, the shaft is not the weak part in any of the tests, so really, if we wanted to push it, we could thin the wall even more (if that is possible). I posted the link to the UIAA specs in an above post. Take a look at it and you will see what loading the shaft has to be able to withstand. I think the worst one is the shaft, fixed on one end, and a load of 550lbs or so @ 500mm on the other end. Let me know.
This could get really good!

To answer a few of your questions:

I'm assuming you make carbon shafts at work? Yes.

First off, how much is this going to cost to have you "whip up" a custom one? This was supposed to be a DIY project, not a full production product :)

A LOT … actually if we make this simple and just do a round shape it won't cost a thing as I already have lots of tooling in the mentioned diameters. Thinking you just want a few tubes to play with, not planning on selling these ?? Going oval or with a bend can be done BUT now you are talking additional cost and I wouldn't even suggest we go down that path unless you are thinking about making and selling thousands of these.

Secondly, what type of capabilities do you have? Can you make any shape out of carbon? Or just round shafts? Can you make a shaft with a bend in it? How about a oval tube with a bend in it?

See above.

The carbon shaft I have been looking at getting (Macqc.com) has in ID of .75" and and OD of .82". However, if you can make any size, I will change that.

I have standard size tooling available without having to buy anything. .75", .6875", .8125", 1.00" etc.
OD you are looking for doesn't matter. I can make any outside diameter as that is based on the number of wraps of the carbon. 0.035" wall thickness sounds good to start with. I need to look at the head insertion depth and will look at adding some fiber orientated 90 degrees to add some hoop strength.

In one of your first posts on this thread you mentioned the carbon being 20% stronger. The numbers passed on to me from macqc show the carbon being several times stronger then aluminum (ie. 295 ksi tensile)…can you achieve these types of numbers? In my design, the shaft is not the weak part in any of the tests, so really, if we wanted to push it, we could thin the wall even more (if that is possible). YES

I posted the link to the UIAA specs in an above post. Take a look at it and you will see what loading the shaft has to be able to withstand. I think the worst one is the shaft, fixed on one end, and a load of 550lbs or so @ 500mm on the other end. Let me know.

As soon as I get a break from work I will check out the site and see what kind of loading the shaft will need to take.

This could get really good!

OK Kevin, we'll stick with the round shaft until I open up a factory ;)

An ideal size would be 0.6875" ID w/ 0.035" wall thickness (Ref. 0.7575" O.D.). This leaves enough meat on the OD of my Ti (0.785") to cover the cut carbon ends. The length can be 45cm for this one (the head and pick will make it 50cm).
I currently have the head inserted into the carbon shaft a depth of 0.80".
Keep me posted – and of course, include a shaft of your own personal desired length – I'll stick a head/spike on it and send it back.
Thanks Kevin.
Steve

Steve,
First prototype carbon tube stats:

OD. has NOT been precision ground. Not ground appears to give a nice grip feel ?? You can tell me what you think after seeing it.

Length is 19.0" as the tube has not been trimmed to length yet.

ID is 0.6875" as requested.
O.D. is 0.770" (aprox. 0.04125" wall thickness)
Lay-up of prepreg is 20% of plies in +/- 45 orientation to resist torsion in striking
20% in hoop for crush resistance
and 60% longitudinal for stiffness and strength along that axis.

40% of the build uses low resin content standard modulus material and 60% of the build uses low resin content intermediate mod.

Weight is 45.2 grams (1.59 oz) (about 48.7% lighter then the alum tube you made)

Looks to be about the correct stiffness and weight. Let me know what you think Steve.

Kevin

Kevin,
Sounds great!! Perfect timing aswell…I just received confirmation that my titanium shipped today. I'll adjust the dimesnions of the axe to match what you have posted. Send me a PM regarding payment and shipping. I'll keep those interested with the results as I complete more of the project.
Thanks alot for doing this.
Steve

I received my Ti yesterday and left it with the guys to cut over the weekend. I'm going to machine the head stem and spike tomorrow. Should be able to have pics up early next week. I ended up squaring off the adze as it seemed to be the better/common design. Even using the titanium gives me a total axe weight of under 4.5 oz. for 50cm length.

Fascinating!

> Even using the titanium gives me a total axe weight of under 4.5 oz. for 50cm length.
Just remember in all of this: the lighter the axe, the less 'strike power' you get. So being fussy about the adze may not win too much.

Cheers
Roger

i just found this thread and wow! i cant wait for the next "installment". what is the total cost of this whole production going to top out at?

Chris,
Good question…having the shop available for use, machining the parts myself, and Kevin E sending me a free carbon shaft (he shipped it yesterday!) – total cost will be quite low.
I really only have to pay for the titanium itself, about $20 or so per axe – oh, and I'll have to purchase some epoxy to bond the shaft to the parts.
However, I have spent many hours working on it, design/re-design, manufacture, including a small accident Sunday requiring me to remake the head stem and spike (my skills have dwindled over the years). If you have access to the facilities required, then it is definitely a project to take on…if you are going to farm out ALL the work and material, I imagine a "one off" would be quite expensive.
Steve

> However, I have spent many hours working on it, design/re-design, manufacture,
These things often become 'many DAYS', not hours :-)

For those wondering if I forgot about this project.
Had a few delays over the past couple of weeks….

I received the carbon shaft from Kevin – Thanks! The unpolished (ribbed for pleasure) texture is great for grip. Build quality is top notch – strong and uber light!

I machined the head stem and spike and modified for proper fit to the shaft. Not to toot my own horn, but they look sharp!

But…after fixing the compressor on the plasma cutter last week, my friend cut the titanium over the weekend and I just got it back this morning. It is basically scrap. Apparently too much moisture in the system. So, I have to order more Ti this week and hopefully get the plasma set up and the Ti cut next week.

Winter is in full force up here, so testing will begin as soon as the axe is compete.

Steven,
Make sure and include some pictures SOON as I'm really looking forward to see how it is all coming together!

Kevin

Ok, so here is the situation. I had to order more titanium twice as the plasma cutter destroyed the pieces again. Due to extreme rage, I scrapped the plasma idea and ended up using the water-jet cutter to cut my pieces out and they turned out great. I took it to get it welded today and there were no problems, except the smallest wire they had was 1/16 so the beads are a little big. I'll leave more room next time. All I have left to do is bond the head and spike to the shaft via Kevin's instructions.
I'll post some pics this weekend when I unpack my camera (I'm in the middle of moving). It's coming together…
Steve

m.y.o.Gift.. Merry chirstmas!

New pics as promised.
I still need to clean up the head and anodize it along with the spike. Then I just have to bond it to the shaft and it wil be ready for service. I'm going on a trip in the first few weeks of the new year, so I will be able to test it out. Best part of all, it comes in at 3.9 oz.

Here's a pic of the whole axe. It's not bonded yet, just fit together.

Three piece welded head. The Adze still needs to be chamfered.

And of course, the scale shot. The epoxy will be the only extra weight on top of the 3.9 oz. I can't imagine much of an increase.

Merry Christmas!

Looks to me as thought the 1/16" Ti welding wire was about right.
Now we need to know how it goes in the field. We await … :-)

Wow… Very Very NICE!

Looks awesome :) This has been such a cool project to watch! Can't wait until you get to try it out and report back.

In for 3, but the shipping kills it – ;)
seriously tho, this is one of the coolest projects ever. Happy New Year and where you going?

Thanks for comments guys, this project has been good fun for me aswell.

Paul – I'm just going on a 3 day snowshoe trip up to Ishpatina Ridge. It's not a mountaineering trip by any means, but I'll find some nice slopes to see how the axe stands up to a little abuse and general use. Afterwards, I "may" test it to failure just to get an idea of it's capabilities. A bunch of my buddies all want one so I'll probably end up making a few more mods (Rev 3 if req'd) before spitting out a small run. I just hope Kevin can get me a good price on those carbon shafts ;)

Happy New Year!

Hi all,
first post here, but wanted to say how impressed I am by the way this project has come together through the quality input and production skills.

I'd be interested in having one of these to go with my MYOG Ti snowshovel with carbon handle. Looks like shipping to the UK wouldn't be toooo heavy anyway. ;)