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This Instructable is being entered into the 3rd Annual Make it Stick contest and the Halloween Props contest. Don't forget to vote... even if it's not for me. :(

My wife and I decided to dress up for the release of the Avengers movie earlier this year. Considering the fact that I had been growing my hair out and that I had a beard we thought it appropriate for me to go as Thor. I decided to start by making Thor's hammer, Mjolnir. After all, what's Thor without his powerful hammer?

(See the rest of the costume here)

Step 1: Supplies

For this project I used:
-Foam Blocks
-Masking tape (wide)
-Glue
-Wooden Dowel
-Leather scraps
-Cardboard
-Silver paint
-A serrated knife
-A file
-A few other odds and ends

Step 2: Sledge

The first thing I did was figure out what size I wanted the main body of the hammer. You may want to size it somewhat appropriately to yourself or you might want to try and keep it accurate to Thor. I ended up making it about a foot long, and about six inches tall and six inches wide. I used some thick insulation foam that I happened to have, but you can use floral foam or regular foam from the craft store. I used a serrated knife to shape it. First I made sure my block was the right size. The foam I had wasn't thick enough so I used two pieces. I cut the edges off to make it a sort of oblong octagon. Then I cut the corners off to give it that geometrical-semi-rounded look that it has.

After getting it the right shape I used my file to smooth it out. If the foam you use doesn't seem to need this then you can skip it, but the stuff I used got really rough when I cut it. I've heard using an electric knife (the kind used to carve turkeys) helps alleviate this problem but I don't have one so I had to just cut it as smooth as possible and file it the rest of the way.

Once I was happy with the shape I covered it with masking tape. I used a wide roll so I'd get good coverage. I'm not by any means going to pretend like this is the best method, but it was cheap and easy. If you do it this way make sure you keep the tape fairly straight and very smooth.

I drilled a hole into the bottom using a hand crank drill. You could probably use a regular drill you just have to be very careful because of how soft the foam is. Make sure you don't make the hole too big. You'll want the handle to be a snug fit.

Step 3: Topper

For the disc on the top of hammer I just used my roll of masking tape as a template and cut out a piece of cardboard. Depending on the size of your hammer you might have to use a different template.

I taped the disc up to match the rest of the hammer and glued it to the top. To make sure it adhered well I put it upside down on the table and put some heavy blocks on it.

Step 4: Paint

I gave both the sledge and the wooden dowel a couple good coats of grey and then a light dusting of silver.

Step 5: The Handle

There are a lot of different variations on Thor's hammer so you can do the handle several different ways depending on the look you're going for. If you want to go the really simple route you could wrap it in strips of cloth but I wanted mine to be at least kind of similar to the movie so I decided to do a leather grip. I figured out how long each strip needed to be to go around the dowel and then cut them out in a sort of wavy pattern. Each strip was about an inch and a half in height. You can cut them out with a really strong pair of scissors or a good utility knife with a brand new blade.

After I had them all cut out I punched holes in them so I could sew them. I used a leather punch, but you can use an awl or a nail or really anything sharp. I sewed them on with a large needle and some waxed thread. I also put glue under them as I sewed them on to make sure they stayed in place.

For the final touch on the handle I attached a loop on the end. I cut a thin strip of leather and using really tiny nails I tacked each end of the strip to opposite sides of the dowel. Then I cut another strip of leather and wrapped it around the butt of the handle to cover where I had attached the loop. To attach it I used the same method I used for the rest of the grip.

I put rubber bands around each strip of leather as the glue dried.

Step 6: Finish

The last step is simply to glue the handle into the hole you made in the sledge. If you find the hole is slightly too big you can wrap tape around the dowel rod until it fits tighter. Then just cover the dowel with glue and put it in the sledge. Make sure you cover it really well with glue. Also, when you put the handle in make sure it stays straight until the glue is totally dry. You don't want to turn your back and find that it dried crooked.

Now you're ready to save the world!
<p>I made a slightly different version from a mixture of different tutorials including this one! MInes made from cardboard! </p>
looks great
<p>Awesome! It turned out great.</p>
<p>Awesome!! Comic Con here I come!!</p>
<p>Where did you get the foam, and how soft is it? Like, if someone were to be hit with it, would it hurt?</p>
<p>I got it from my work but it's just insulation foam. You should be able to get it at your local hardware store or building center. If you can't find it thick enough you can laminate pieces together. As far as how soft it is, that's kind of a tough question to answer. It's a pretty light material so it would be hard to inflict much pain but it would still hurt if I konked someone upside the head with it.</p>
<p>At risk of sounding stupid here, how did you attach the leather strips to the wooden dowel? I'm assuming you glued the leather and wrapped it around the dowel AFTER you sewed them? Just wanted to clarify =) It looks great, I am soo going to try this!! Any ideas on where I can find leather strips like these to buy? Thanks =]</p>
<p>I actually glued and stitched almost as one step. Basically I put some glue on a strip, positioned it where I wanted it, and sewed it up. I just used a standard PVA/craft glue so the dry time isn't that fast. It gives you a little time to work with it. As far as the strips themselves, I recommend buying a bag of scrap leather from Tandy, ebay, or a craft store and cutting them out. You can get them the shape you want and you should have a good amount of leather to play around with afterward. Technically you can also buy strips of leather from Tandy but it's usually more expensive to buy it that way and you will have less options when it comes to your final shape.</p>
here's my hammers handle. I havnt casted my hammer head yet
<p>Very cool!</p>
looks great!! making one myself right now too. sand casting the head from aluminum and made a handle from aluminum pipe and some vynil.
I need to try this!it looks so awesome! As soon as I get the materials! I also want to make an iron man helmet!
I made one out off two bricks and lots of cement and it's really heavy! well me and my friends were at contraction sight, we were bored so we did this! we tried to get it home and make a nice handle like Thor's &hellip;&hellip; but the contactor of that place took it away from us cause we stole their cement and bricks ;DD<br>it's still there&hellip; one day we will get it back cause only we are worthy!
<p>That is quite impressive. A word of advice, a lot of times you might find contractors willing to give you scrap material that they would just throw away otherwise, if you ask nicely. ;)</p>
i can't upload photo!! why!!
O here it is!
<p>Hey! I'm making this for friday but I can't figure out how you've done the stitches in the handle!</p>
<p>Basically I just had to angle the needle through the holes. More often than not I put it through one hole and out the top and then angled it back under to come out the next one. If that makes any sense. I also kept the thread a little loose until it was stitched and then tugged the strings tight, tied them off, and tucked them under. Hope that helps. Good luck!</p>
<p>Definitely a very good and cheap idea for my childrens. thank you.</p>
Haha cool
<p>Thanks.</p>
<p>thanks alot.</p>
<p>can we use normal white foam</p>
<p>You can use pretty much any kind of polystyrene foam. I just used this grey stuff because it was what I had around.</p>
<p>can we use normal white foam</p>
<p>can we use normal white foam</p>
how should we put the tape
so what are you makin now
Currently I'm working on a DOTA 2 Juggernaut mask, a Sith Stalker helmet, and an assortment of other smaller projects.
could you tell me how to make this
That's kind of what the whole instructable is. Just read the steps and you should get a pretty good idea of how to make it. I don't know what else to say other than the instructions I've put in each step.
this is super cool
Thanks! Welcome to instructables!
That hammer looks really great! Thor's hammer might be my favorite superhero prop to make, there's so many different and cool ways to do it.
Haha thanks, you're too kind. I'm pretty happy with it but next to yours it's like &quot;Wuh, wuuuh&quot;.
Odin's beard, this is great!
Haha awesome, thanks.
I really love how you did the handle! Wonderful detail! Did you keep track of how you put the rest of the outfit together? It looks great!
I hope to be posting the rest soon! I'll also be posting my wife's Hawkeye costume.

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Bio: I like to think of myself as a renaissance man. I'm interested in a lot of things, but most importantly I'm interested in ... More »
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