DIY Metal Texture Hammers From Railroad Spike

I had recently done some copper work by making pulls for my apothecary cabinet. I liked working with copper and would like to continue to work with various metals in future projects.

I got inspired by a few folks to make the metal texture pop. Danthemakerman made two hammers from one railroad spike which I thought was very cool. I have some squirreled away and wanted to tackle making a couple hammers myself. Not only that, but, as luck would have it, the Silver Meister on YT came across my, "Hey, you may like this" feed. After seeing his silver smith hammers I knew what I was meant to do.

Safety gear for sanding, grinding, etc.

Railroad spike or similar spare metal

Something to cut the metal, I used an angle grinder

Clamps, Vise, Pliers to hold the work

Sandpaper or wire brushes to remove any rust

Metal punches

Drill & bits to make a holes

Cutting oil

Various files/rotary tool

Marker

Wood to make handle(s)

Saws to cut stuff

Sandpaper for the handle

Copper for testing out hammers

Blow torch to help destress the metal and add "color"

More sandpaper for the copper, finer grit like 500 or higher

First thing was busting the rust off of the railroad spike, pic 1 & 2. After that we want to get it ready for separation because I wanted to get two hammerheads out of the one spike. In order to do that, I need to punch a hole for my drill bits and then drill out where the handles will go, pic 3 - 8.

I used some cutting oil and various drill bits in order to step the process little by little because I didn’t want to take too much metal out and risk ruining my bits. It’s a slow process but patience is a virtue, or so I am told. After the holes are drilled I proceeded to use a rotary tool and files in order to make the smooth recess for the handle to rest, pic 9 - 13. Luckily, railroad spikes aren’t very hard so this was a relatively quick process.

Once that was done, I cut the spike in half with an angle grinder, pic 14 - 16, but you could use a hacksaw as well.

I have my pieces ready so it’s time for the first pattern: The Checkerboard. It also kind a looks like a meat tenderizer but take it for what it’s worth and let’s move past it. :)

I filed the end flat (pic 1), marked the face (pic 2), and then used a tiny triangular file to make a couple grooves (pic 3). At this point I thought that I could make the process easier by taking those grooves to the bandsaw fitted with a metal cutting blade. The idea is to help my larger triangular file ride those grooves, pic 4. Once those cuts were made, I use the bigger file in order to make my checkerboard, pic 5 - 7.

The other end of the…head end of the spike was going to be used for the next pattern: The Bubbles.

For this I used a diamond round bit on my rotary tool and just made several passes until I was satisfied.

Before using the rotary tool, I thought about maybe just hammering the end with some punches. I suppose you could if you had that available.

To get the third pattern out of the head end of the railroad spike, I stuck it in the vise and used my angle grinder to thin the end out even more, pic 1 & 2. Afterwards, I used a small hammer to create a curve in the newly thinned metal, pic 3.

Moving on to the spike end now, I wanted to create an irregular pattern. I used a marker to draw some shapes and then took the round bit on my rotary tool once again to cut the grooves in. This was another process where taking your time, limiting your coffee intake, and steadying your hands really helps.

I saved the easiest one for last. I heard you have to 'Eat the Frog,' aka do the hard parts first. That way, you get them off of your plate.

Here, I take the actual spike end and make it flatter with a file or sandpaper.

With all five patterns completed it was time to insert the hammer handles. For the smaller spike hammer, I had on hand a spare handle from an old kitchen utensil. Yes, I am a packrat. For the head end of the railroad spike I used a piece of oak that I shaped on the bandsaw and sanded down.

I had some leftover copper pieces from my apothecary cabinet build and so I decided to take five of those for each of the five patterns. I used a steel block that I had laying around as a base and started hammering them out.

Like I mentioned in my copper turtle video, continuous hammering puts a lot of stress on the metal. It’s good to ease those stresses by taking the copper to the flame. For this I use my blow torch for just about 10 seconds for each piece. This also gave a darker tone to the copper which was good for sanding later in order to contrast the textures. I use 500 grit sandpaper for this and just made slight passes. I suppose if you had or purchased some liver of sulfur, it would make a more pronounced contrast but your shop will smell like farts. I didn't even know sulfur had livers. Whatever.

I really like how the leopard, the flat bar, and the checkerboard patterns turned out. The bubbles I had better hope for and the curved part I had to use a second hammer in order to utilize. It was cool as a concept, or so I thought. I probably wouldn’t use this in the future unless I really made that curve a little bit curvier and more pronounced. It may just need some time with the rotary tool / filing. I suppose the curve on the hammer needs to be longer and more flat but that is just speculation.

This was a really cool weekend project. I like how this adds a little bit of texture to copper. I think there is some room for improvement but the concept works and I really enjoyed making them.

Let me know in the comments if you have made a similar hammer or if you have purchased a hammer that has a really cool texture that you like better than the ones I display here.

Now lets make something to show off besides . . .Pirate coins?!

I figured I would use a couple of the checkerboards to make into earrings.

I used a small punch, pic 1, to allow a spot for my 1/16-inch drill bit to "bite" into the copper and went to work, pic 2 - 4. This left a small burr on the backside, pic 5, so I used a small file to smooth it out, pic 6.

I then ran a loop for the actual earring though the newly made holes and they are ready to wear out on a night on the town!

I think it is fun to create such unique things. Given a small time slot, you could make various earrings, bracelets, or necklaces in a similar fashion to give as gifts (or keep for yourself).

I hope this perks your ears up (pun intended) and inspires you to make your own. See you next time!