I modified an old ball peen hammer.
To make the hammer, I marked guide lines on the sides with a sharpie, then ground down the top and bottom to the lines using a 6" bench grinder with 60 grit wheel. I dipped the steel into a bowl of water often to keep the steel from getting hot and destroying the temper of the steel. Once it was roughed out I used a finer grinding wheel to smooth the surfaces and refine the shape. I then used a file to blend and final shape the head. I used an orbital sander and sanded the piece to a uniform finish using 60 grit paper. I then hand sanded with 100, 150, 220, 320, 400 sand papers to get the head nice and smooth. I then polished to finish the hammer.
Jim
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