Instructables
Picture of Rubber Mallet Mjolnir
And lo, from the bards of Marvel came a tale so stunning, so touching, so blockbusting, that throughout all the land, the people were shaken. And yea, the cosplayers did come-

Look, the point is that I made a Thor costume for San Diego Comic-Con, and I needed Mjolnir to go with me.

You can find several tutorials on this site for replicas of Mjolnir, but I needed something in between cardboard and metal. I had a couple criteria for my hammer: it needed to be light enough to carry around all day at a con, it needed to be small enough to fit into my suitcase, it needed to be sturdy enough not to be crushed mid-flight, and I needed to be unable to injure someone with it.

So here, for your entertainment, is what I came up with: a foam hammer built around a rubber mallet. Turned out pretty slick, in my oh-so-humble opinion.
 
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Step 1: Supplies!

Here is everything you will need:

For the base

- 1 16oz or lighter rubber mallet. These run about 5 USD at Home Depot.
- 6 blocks of dry floral foam, 8x4x3 in. Floral foam comes in three varieties: wet and two kinds of dry. You want the softer kind of dry. You should be able to nick it with your fingernail (but don't).
- several sheets of thin foam, similar to these. Whichever ones you use, they need to be at least ten inches on one side and about seven on the other.
- 1/2 to 3/4 yard of very thin, stretchy fabric. I used leftover bathing suit liner from a Question costume from long ago, which was ideal. You'll be working from the selvage in, so the width (45", 60", etc) of the fabric is immaterial (ha!).

For painting

- gesso. I used most of a 16oz bottle.
- foam carving utensils. I used a regular-old butter knife and a spoon.
- a variety of paintbrushes. You'll want a bunch of foam ones for glue, at least one big one for the gesso, and some for the paint.
- a 2" foam paint roller
- a variety of acrylic paints. You'll want gold and silver metallics for sure, along with flat grey and white, but if you find one color that's exact, go with it.
- palettes for the paint
- a small bottle of brush-on matte acrylic sealant

For the handle

- strips of leather or leather-like vinyl, enough to wrap around the handle. Remnant leather is just fine.

Notions

- a pair of sharp scissors. Foam sheets do not like dull.
- a few disposable plastic cups (Solo cups)
- a frankly ridiculous amount of Tacky Glue or similar substance. There are glues made for floral foam, but Tacky Glue didn't have any problem holding.
- a ruler. I strongly urge you to invest in a Dritz See-Thru Dressmaker's Ruler or similar product. Changed my crafting life.
- a pen or mechanical pencil
- some straight pins, preferably the ones with the flat heads. You will not be getting most of these back, so don't use Mamaw's that she used to sew your baby clothes.
- a drop cloth or a LOT of newspaper


This looks like a whole lot of supplies, to be sure, but a lot of this stuff is stuff that you probably already have at the house. The biggest expense was the gesso, which ran me about 16USD for 16 oz, and I had almost all the paint already from other projects. Minus the gesso, this piece cost me about 40USD.
monsterlego2 years ago
Awesome
mcangmar (author)  monsterlego2 years ago
Thanks!
That turned out Awesome!
mcangmar (author)  Penolopy Bulnick2 years ago
Why thank you! :D