How To Make Thor\'s Hammer Mjolnir Small Projects

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.

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)

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.

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.

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.