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A note on fitting forged heads.

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Rod:
I would not wish to discourage those who are experimenting with making their own heads, but the standard towards which they should be directing their efforts should be to make a rolled cone of quite uniform dimensions and then to finish and fit to the shaft such that the ferrule is flush to the shaft, it's base resting firmly upon a "shoulder" in the shaft.
The cone of the shaft should fit the shaft as fully as possible and without voids in the tip.
Mark Stretton has demonstrated that a shaft with a void in the tip of the ferrule is likely to be less efficient
in penetration since the shock of impact is likely to loosen the head from the shaft.
It is an ongoing bone of contention between myself and Hector that I have a go at him when I consider the ferrules of his points to be too irregular.
I have often speculated as to the possibilty of forming the rolled cone on a standard mandrel so as to facilitate some uniformity of fit.
I daresay that in the day production standards varied somewhat, as they do now, but I am equally sure that the better marksmen were more picky than the run of the mill fellows when it came to selecting their gear for more critical work, though of course, for barrage fire, where the priority was on rate of fire and holding to a distance then unsorted sheaf arrows would be used without any opportunity of selection, other than by the maker or by inspection upon delivery.

Rod.

SimonUK:
It's very tricky filing down the taper to fit exactly.

I've been wondering whether it's possible to put some kind of black dust inside the ferrule, tip it out again then insert the tapered shaft. The dust should appear on the wood at the sites where it needs to be filed some more.

MattE:
Simon, you can use the powder to show where to remove material for a perfect fit but I see quite a lot of work with this method. I would think the use of a mandrel for uniformity of the taper would be best. If heated to the right temperature and the use of flux , the seam can be hammer welded to eliminate any spreading on impact.Another option is to braze the joint.
I haven't actually made heads like this, this is only a theory.

Rod:
If I had to make the things day in day out I'm sure that I might take the time to produce a suitable mandrel and this would speed the task of making more uniform fitting heads.
But I have no source of evidence on this subject.
Mark has demonstrated that leaving a void in the tip of the ferrule is counter productive as affecting penetration of a hard surface such as plate.
Given the "hammer drill" nature of penetration of plate I can understand how any weakness in the tip will result in separation.
Rod.

MattE:
Rod, a void at the base of the shaft would surely spread the ferrule open on impact.I have no proof but I am certain in my mind that a mandrel was used . Man has always been smart and by looking at the sophisticated machinery of the day, this minor problem would have been eliminated rather quickly. Heads were being hammer forged by other cultures.     

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