Electrolysis, try it! It makes the metal for a while more brittle if you overdo if, but it will take out nothing but the rust. Nothing that should affect something as little as a hatchet to make it fail...and the material goes back to its original state eventually. (The Hydrogen atoms that "seep" in-between the metal ones find their way out eventually.) I used an old PC power source, worked perfectly! Also, it seems to me you should put the head the other way around. Look at the curvature: should be deeper at the bottom. The hole should be wider at the top, so that you can drive a wedge and the flare would retain the head. I actually like to leave the handle proud at the top (not flush) and drive the wedge a little bit lower. This way, you have the two separate splits of the handle adding extra friction/grip by pushing the sides. Nice one, all that being said!
Electrolysis, try it!
It makes the metal for a while more brittle if you overdo if, but it will take out nothing but the rust. Nothing that should affect something as little as a hatchet to make it fail...and the material goes back to its original state eventually. (The Hydrogen atoms that "seep" in-between the metal ones find their way out eventually.)
I used an old PC power source, worked perfectly!
Also, it seems to me you should put the head the other way around. Look at the curvature: should be deeper at the bottom.
The hole should be wider at the top, so that you can drive a wedge and the flare would retain the head. I actually like to leave the handle proud at the top (not flush) and drive the wedge a little bit lower. This way, you have the two separate splits of the handle adding extra friction/grip by pushing the sides.
Nice one, all that being said!