This instructable will hopefully teach you how to make a micro Thor's hammer which you can use as pendant or keychain. I made it for my friend as a christmas gift because she is big avengers fan. It is not difficult project but sturdy hands and a small workshop is needed.
Step 1: Step 1 : Materials
You are going to need a square metal rod (I used roughly 8x8 milimeters), tapping set for making bolts and holes with threads, some power tools, soldering tools and a small piece of brown leather.
First I cleaned my rod using sandpaper attachment on my drill press (you can use files, sandpapers and do it manually)
Than I cut it to length using angle grinder with cutting disk attachment. The length is about 14 milimeters.
Next thing you need to do is to establish bevels on all of it's edges. There are as well several options such as sandpaper, file, bench grinder, belt grinder and many more.
Step 2: Step 2 : Tapping
Because I like challenges I decided to make threads on both the head of the hammer as well as the handle and fasten it this way. I used M2 tapping set.
The hole in the head must be slightly smaller diameter than 2 mm so you can make the thread. For this purpose I used 1,5 milimeter drill bit and drilled a hole in the middle. You must be extra carefull and take your time because these drill bits tend to break really easily.
Than take out the set for tapping and start with the one marked with one stripe across - this one is for marking the threads. Make sure you are perfectly squared and again take your time ... these things break just because you look angry at them. A little bit of oil helps too. The one with one line is followed by one with two stripes and the thread is finished with one with no stripes on it.
For the handle you can make your own threaded rod or cut some bolt to length.
Step 3: Step 3 : Grinding and Polishing
Now it's time to level all sides, grind them a bit and than polish it all. I decided to do this step all by hand because I find this way the most accurate and the piece is very small so not much grinding at all. I started with 240 grid sandpaper followed by 400, 800, 1200 and finished with buffing wheel on my rotary tool.
Step 4: Step 4 : Finishing
My soldering iron is used to attach small ring to the handle. You need to clean both pieces, warm them up and use some kind of flux to properly solder the joint.
Than I cut a narrow piece of brown leather and wrapped the handle with it. To make sure it does't unwrap I used super glue.
I even used a needle to "carve" runes on the beveled edges, but it is not very visible.
The last step is to add another strip of leather as shown in the fifth picture.
Step 5: Step 5 : Photos
I am very pleased with the result. I consider this a perfect gift with little homemade box and a great way to relax for a few hours because final exams are coming and there is no better way to escape from all those responsibilies then to make something in your workshop while your favourite music is blasting in your ears.