These are instructions to make Thor's Hammer out of plywood. It is made for adults and is very durable. To make a hammer for a child's Halloween costume you should reduce the proportions by a third to account for smaller hands and strength.
Step 1: Instructions to Make Thor's Hammer
Wood Purchase List:
- One half sheet - ½”, 3/8”, or ¼” plywood – you either go for weight reduction or strength, your choice. I used ½” plywood. ¼” would be better for children. In case any mistakes are made it is good to have a little extra around.
- One - 2 x 2, or 2 x 4 ripped in half or 1 dowel 1 1/8” - 2' long
- Four faces ripped 22 ½ degrees on the long side – 8” x 5” - (as measured on the long bevel)
- Four thin post pieces ripped 22 ½ degres on the long side – 8” x 1 1/8” - (as measured on the long bevel)
- Eight pieces 5 1/8” on the long side, compound mitered 11 ¼ degrees and beveled 22 ½ degrees on each side
- Eight pieces 1 ¼” on the long side, compound mitered 11 ¼ degrees and beveled 22 ½ degrees on each side
- Two pieces 6” square mitered at 45 degrees on all sides and then cut all 4 points of the square 45 degrees at ½”
- One 2 x 2 rounded to 1 1/8” approx 14” long, depending on your size
- One 4” piece of 2 x 4 for attaching the handle inside the hammer
- One oval 5” x 3 ¼” at the extremes made of ½” plywood
- approx 30” of vinyl that simulates leather for the handle covering
- metallic paint, spray or brush, latex or oil
- black paint, brush, latex or oil a tack for the bottom of the handle
- hot glue gun
- small paint brush for the symbols, mixing black and metallic
- Table Saw
- Miter Saw
- Power drill with a 1/8” bit and a 1 1/8” spade bit
- Jig Saw, coping saw or band saw Hammer
- Sand paper or Sander
- Hot glue gun or carpenters glue & brad nailer (hot glue is much easier)
note: You can't really avoid these tools for this project
Creating the main faces and basic box:
Set your table saw fence to 5” and your blade to 22 ½ degrees, and rip down the ½” plywood. The final top bevel width of the wood will be 5 ¼”. Cut 4 pieces to 8” on the miter saw. Repeat the operation, but set your fence to 1” and cut 8 pieces to 8” on the miter saw. Drill into one of the larger faces in the very center with the 1 1/8” spade bit to make room for the handle. Use a hot glue gun to glue up the 8 pieces to use as a guide for the rest of the build.
Creating the side faces:
At the table saw with the fence still at 1” rip numerous pieces with the 22 ½ degree bevel on both sides. The lengths should be about 2' to handle easily on the miter saw. Set your compound miter saw to a 11 ¼ degree miter and a 22 ½ degree bevel. With the bevel down cut the 2' beveled piece from above anywhere on the end to start the angle. Once that cut is made take the piece over to the box you have so far and place the piece on the long side of the box (see the video for a visual) to mark for the cut. Using a bevel hand tool really helps to line up your cut at the miter saw unless you have a laser. Repeat for the 8 long pieces and then the 8 small pieces. Use hot glue to attach all the small pieces to the sides of the hammer box.
Make note that we have not yet cut the two face covers so that we have access to attach the handle.
Cut a piece of 2 x 4 four inches and drill a 1 1/8” hole in the center. Cut the dowel or any 1 1/8” handle to 14 inches (or whatever fits your hand better) and put it through the hole in the bottom of the hammer box, and then place the part of the 2 x 4 that you cut at 4 inches inside to cap the handle. If everything fits then remove it, add yellow glue and secure the handle to the box by drilling a 1/8” pilot hole into the long grain of the 4” piece of 2 x 4 and either side of the handle, use a 2” drywall screw to secure it on either side. With the handle attached securely we are ready to cut the final two pieces of the hammer to close it up.
On your table saw, with the blade set at 45 degrees and the fence set to 5 1/2", cut a 6” square. Once you have the square keep the blade angled and tilt your table saw's miter gauge to 45 degrees and knock off a ½” of each of the 4 corners. Repeat one more time. Attach the final pieces with hot glue.
Using a jig saw, coping saw or band saw cut an oval approx 5” x 3 ¼” and hot glue it to the center top of the hammer.
Finishing If you desire you can fill in any gaps with spackle or putty. Let dry and sand smooth. Add the metallic paint. A few coats are suggested. Color and design are up to you. See the video for how I managed it.
Cut the vinyl to about a 1 inch strip, approx 20” long. Wrap around the handle, when satisfied attach with hot glue.
Step 2: See the Video for More Information!
In the video I go over step by step how to adjust your saw settings and guide you through the process. The angles are a little tricky so I wanted to add the visual touch and show you how I set the miter and table saws. Thanks for checking out the build!
You can always see more projects and videos on my youtube channel DarbinOrvar