Thank you for your post Big Wave. I think you had posted that hammer in another thread several years ago. I was inspired by the picture you posted of that hammer built for you by Randy. We have been using a mallet to pound them flat on a rock. I wanted to make a hammer like yours for a friend. So, I took a 4 pound Estwing sledge I had in my toolbox and welded it (worlds ugliest welding job) to a 5 inch disc, a friend of mine, cut for me with a plasma torch out of ¼” scrap . I had a 12 x 12” ¼” inch plate I paired it with. I ended up painting all the metal with some white Rustoleum to prevent rust.
I have never seen cans crushed this flat. They are literally as flat is a quarter. My old lever action can crusher could not do better than half-inch because it can’t flatten the dome on the bottom of aluminum cans. The hammer destroys the dome and that’s how you get them so thin.
My friend was super happy with the gift. However, he said that he had to be careful while pounding not to rap his knuckles on the ground. He suggested angling the hammer up a little when welding it to the disc. I also realized 12”x12” ¼” plate is way too big. You don’t need nearly that much steel.
I decided to make one for myself. I went on Amazon to order an 8”x8” ¼” plate and noticed one of the options was stainless steel. It cost only $4 more so I got it, a 5” diameter ¼” stainless disc and a 1.5 kg stainless steel sledge. The stainless steel sledge cost twice what the steel hammer in my first one did. The stainless plates barely cost more than the steel options. I already had the gas to weld stainless steel and stainless wire for my mig welder. I ground an angle on the face of the sledge, welded it up (and did a much better job this time on the welding.) and here is the result.
it crushes cans just as flat as the first hammer, but it’s a knuckle saver thanks to the slight angle, and I didn’t have to paint it or worry about rust since it’s stainless. Thanks for your post Big Wave and the pictures, I know it wasn’t really what the OP was asking about but it was very helpful for me!