If you can get the head off the handle right now, it would make for
a great opportunity to improve its finish. Cheap hammers usually come
with a cheap finish: mill ground with sharp edges.
Sharp edges usually aren’t desirable, because if you hit a bit of
metal in any way other than exactly perpendicular, that edge will
leave a pretty little crescent-moon shaped scar that will take ages
to sand out. You can dress a hammer with its handle still attached of
course, but then you’ve got a foot or more of wood to get in your
way.
When I bought my goldsmith’s hammer, also cheap, also with a loose
handle, I pulled the handle out and used a bench grinder to put first
a bevel the entire way around the broad face. When I had an even
bevel, I ground down the corners again to make a smooth, shallow
dome. I did the same to the pein, to make it rounded rather than
angled. I then smoothed out the grinding marks on both ends with
emery paper. I can’t remember exactly what grit I took it too, but
I’m pretty sure it was either 220 or 400. It wasn’t a mirror polish,
because I’ve got a separate hammer for planishing. The point is to
make sure you get out each and every single bit of the rough texture
left by the grinding wheel.
That done, I slipped the head back on the handle and used a mallet
to tap the head down until it would go no farther. I cut off the
extra wood so that there was just a tiny bit of handle sticking out
over the head, and then took a small wedge and drove it down into the
wood, to spread it. A nail would work, although it might be good to
grind down two sides of it so that it is rectangular in cross
section, rather than round: round is more apt to wiggle out over
time. If you mess much with gravers, the cut off ends left from
shortening them to fit your hand make excellent wedges for small
hammers.
Anyway, drive the wedge in and see if it is still loose. If it is,
and there is room, drive a second wedge. If there’s a great gap to
fill, no number of wedges will be enough to keep the head on tight,
and it would probably be best to just start over with a new handle of
the proper size.
Alternatively, when my father would cut wood for his heater during
the winter, he would leave his sledge hammer and splitting maul
sitting in a bucket of antifreeze. The antifreeze will make the wood
swell just like water, but it doesn’t evaporate when it dries, or at
least, it doesn’t evaporate quite so quickly.
Willis