Metal Work
This is where I first started. I knew how to get metal shiny and it was my one trick for a long time. Years later, I realized that having a good edge is what's going to make your ax fun to use.
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Edge work Set the Edge First
I've gone back and forth on this and I think it's prudent to set the edge first, before doing anything cosmetic. What can happen is I'll spend 30 minutes and 30 sanding disks to get a perfect mirror polish, then re-profile the edge and it eats into my mirror polish and I have to start over (if I was going to). I'll explain the easiest (and least expensive) way to set a decent edge.
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Step 1. Get a golf ball (goodwill has them for cheap, it doesn't need to be nice)
Step 2. Drill a hole in it
Step 3. Put the golf ball on a mill bastard file as the handle
Step 4. Secure the axe head (flat) in a vise
Step 5. Place the golf ball on the cheek of the axe
Step 6. Apply pressure to the end of the file and work it back and forth .
Step 7. Once the edge it uniform, flip it over and repeat on the other side
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Notes: I like using cutting fluid on the file to gum up the metal shavings. The angle you achieve with the golf ball depends on where you place it. You can also move it around (or use smaller wooden balls on different files) to convex the edge a bit more.
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The Belt Sander Method
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Clean up the Poll (the back end of the axe where someone used it like a hammer )
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Polishing: Save it for last
The Best Mirror Polish
The best mirror polishes come from having a uniform surface. Any pitting or swirls are going to throw off the mirror. Polishing a brand new ax is about 10 times easier than polishing something pitted, because it's already uniform (for the most part). That's the main concept.
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Step 1: De-rusting. I liked to get to bare metal first. This means using Evaporust for about 24 hours and a wirewheel after that. Can you skip Evaporust? You can, but it shows you how much hardend steel is left on the head (and if it's worth restoring).
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Step 2. Decide how much of the ax you're going to polish. If you're going to polish the whole thing. Move on to step 3. If you're only going to polish a certain area, use tape (I like masking or painters tape) to set a barrier where you're going to sand vs not. If the axe head is already on its permanent handle, you can wrap the handle in plastic wrap to keep metal dust from getting onto it.
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Step 3. Using your sander of choice, start
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