A friend of mine in PA has been looking for a Snap-On BF633 hammer for some time now. The last (and only) one I've seen was on eBay, it had nicks in the chisel and hammer face, as well as an incorrect MATCO fiberglass handle. With tax and shipping it sold for right at $200, pictured here:
I also have a couple of the BF617 large face hammers with the shrinking face (waffle pattern). Another metalshaper friend of mine has been restoring and selling hammers and dollys for many decades. He told me in all that time, he has never sold a waffle faced hammer.
So based on his experiences, I have little chance of selling one of those shrinking hammers myself, and thought I'd sacrifice one for the other. Here is our attempt to use a hammer nobody wants to make a hammer nobody can find.
Here is our start to the process, using the blacksmithing skills I didn't know I had. The unwanted end was heated cherry red and smacked using BFH to force the hammer face inward. Heat, beat, and repeat. A piece of 1/2-13 all thread serves as our heat resistant handle.
Once our hammer face was "pointy" enough to fit through the jaw of the lathe, the hammer was chucked and the diameter cut down to size for our faux hammer.
Now with the face cut down to size and preliminary polishing done on the lathe, the chisel could be heated and curved to match the BF633 Unicorn.
Some grinding using the Dynabrade air file/belt sander...
Face polished
Handle refitted and neck section thinned out
The tricky part with refinishing the handles is to leave the logo intact.
Prior to final assembly the hammer head was taken to Combs Prototype and Fabrication for some heat treatment in his oven.
Assembled, polished, and ready for a trip to PA where it can be put to work...