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
-Masking tape (wide)
-A serrated knife
-A few other odds and ends
Step 2: Sledge
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
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
Step 5: The Handle
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
Now you're ready to save the world!