Sledge hammer

I'd be VERY hesitant to use epoxy to fill gaps on a heavy-duty striking tool. There is an adhesive made known as 'striking tool epoxy' meant for attaching fiberglass or similar handles, but even this needs a tight fit to work properly. I have NOT had good luck with Gorilla Glue or similar expanding-foam adhesives where they will see impact loads--they typically fail without warning, especially as they age (and not over several years--usually within months and less under heavy use), creating a severe safety hazard. If this is a wooden handle, you'd be better served to get one properly sized to your hammer and then work it down to a tight fit, and NEVER use water, oil, antifreeze or other stopgap measures to tighten it if it gets loose--they're temporary at best and do more harm than good over the long run.
 
I do not have an answer to your question but, if you can swing a 24 pound sledge hammer my hat is off to you sir.
 
JB Weld, not the 5 min cure, because it is Not as strong as the overnight cure is. Would be a choice to use. It works well for most applications.
 
I like to use Loctite Go 2 Glue. It dries kinda flexible so it holds under shock loads like hammer heads. I glued heads back on my cheap fiberglass ball pein set and it's great.
 
I get the 'willies' whenever I see a loose head on a sledge hammer.

Years ago, when we were setting up a tent camp on Taiwan and someone was driving tent stakes with a sledge hammer, the head flew off the hammer and hit another Marine in the head. He died on the spot.
 
like others have said: Tight fit to start, wedges to keep it there. The dryer the handle is, the better when fitting. I use an epoxy compound made for glass bedding of rifle barrels, made by Brownells, to finish it off. Its a 2 part epoxy, and does not get brittle.
 
I have a 20 pounder laying around somewhere. It was bought as just a head at a flee market. Me, dad, and brother have all tried putting handles in it at different times. Never could ever get a handle to stay in that thing. The best outcome that ever happened, was one handle stayed in it long enough to break rather than come out. AND THAT DIDN'T TAKE LONG. The best thing we could of done, is taken it back to the flee market and re-sold it. In my opinion.
 
(quoted from post at 13:36:27 04/16/22)
There is a glue that expands.

Does Gorilla glue expand?

It does not exactly expand. It foams like spray foam insulation.

I would use it for a hammer head.
 
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