How to Weld Thor’s Hammer with Rebars

  • By: Monica Shulz

The mighty Mjolnir has become very popular in recent years, thanks to the Marvel movies. The striking image of Thor wielding his iconic hammer has inspired awe in many followers of the series.

So, in this article, we will walk you through how you can create your very own version of Thor’s Hammer. So, let’s dive in!

And no, don’t worry. You’re not going to need the heat of a dying star to create this hammer.

What will you need?

Here is a list of things you’ll need to build Thor’s Hammer:

  • 2 x 2 inches angle iron
  • 22.23mm diameter iron rebar
  • Leather strips

Cut The Frame from Rebar

Using a power hacksaw, cut off a small piece from the rebar’s end. After that, cut about eight five-inch-long sections for the rebar rod.

Cut The Hammer’s Core from The Angle Iron

Take the angle iron and scrub it with a wire brush to remove any rust and impurities. Mark out two 8.5cm long sections from the iron and cut them out using the power hack saw.

Join The Angle Irons

Take one of the angle irons, and reduce the height of ONE of its sides by about an inch. Do this for the second one too.

Place both pieces together, so they form a rectangular box. Clamp them down and weld them together with a spot welder.

Grind the welded joint down with an angle grinder until it is even with the surface.

Join The Rebar Rods

Take four of the 5-inch rods and lay them out lengthwise, side to side. Clamp them together and weld them together using a spot welder.

Take the other four rods and do the same to them.

Cut Some Additional Rebar Rods

Take one of the rod plates you welded together and place it on the workbench. Place the angle iron core right in its middle.

Measure the distance from the edge of the iron core to the edge of the iron core. Adjust the iron core’s position until the distance is equal on both sides.

Take that distance and cut sixteen rebar rods of that size.

Weld The Rebar Rods Together

Arrange the rods you just cut in bundles of four. Make sure they are all equally arranged, and clamp them together.

Weld them together with a spot welder.

Grind Down The Bars

After joining the rebar rods together, you need to grind them down. Clamp the bars in a vice and go over their tops and bottoms with an angle grinder.

Make sure you remove any protruding welded bits with the angle grinder.

Assemble The Hammerhead

All the pieces of the hammerhead are complete; now it’s time to assemble and join them together. Place one of the 5-inch plates on the workbench. Place the angled iron core right in the middle of the plate.

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Add two of the small welded rebar plates on each side, and finally, add the second plate on top of everything.

Weld The Hammerhead Together

After assembling the hammerhead, clamp everything together. Make sure all the surfaces are correctly aligned.

After that, weld everything together using a spot welder. Ensure you weld all the gaps between the rebar plates and the iron core together on all sides of the hammerhead.

Grind The Hammerhead’s Surface

Clamp the hammerhead with the face pointed directly towards you. Using a grinder, grind the face entirely until a smooth surface is left.

Angle the grinder and go over the edges to create a chamfer there. Do this for the face on the other side.

Unclamp the hammerhead and position it so the iron core is facing upwards. Using the angle grinder, level the iron core until it’s on the same level as the surrounding rebar plate.

Use a drill bit with the sanding attachment and clean the welds between the rebar plates. Turn the hammerhead over and do the same for the same side.

Cut A Blank For The Hammer’s Handle

Take a 1.5-inch thick piece of wood and cut a 3-inch wide section from it using a table saw. Sand down the edges of the blank using an electric sander.

Cut Out the Hammer’s Handle From The Blank

Sketch out the shape for the hammer’s handle on the blank you’ve just cut. Using an angle grinder with a sanding attachment, gently sand out the shape of the hammer from the blank.

Note: Make sure the head of the hammer handle is about 2 inches wide and 1 inch deep.

Cut Some Grooves In The Hammer’s Handle

These grooves are for the wedge that will hold the hammerhead in place on the handle. Cut a groove about 3 inches deep on the handle’s head using a bandsaw.

After this, turn the handle 90 degrees and cut another 3-inch groove horizontally.

Attach The Hammerhead To The Handle

Take the side of the hammerhead with the grooves on it and insert it into the hammerhead. Gently tap it with a mallet until it enters the hammerhead and comes out through the other side.

Take a wedge and apply glue to it. Gently hammer the wedge into the wider groove.

Take some other wedges, apply glue, put them into the smaller grooves, and hammer them in. Next, take a saw and cut out any protruding parts from the hammerhead, so it is flush with the surface.

Finish The Hammer Handle

First, apply a final finish to the wooden hammer handle. You can use a variety of finishes like wax, shellac, linseed oil, or varnish.

After applying the finish, wait for it to dry. Once the finish has dried, tightly wrap a leather strip around the bottom of the hammer’s handle.

Next, take another leather strip and wrap it around the part of the handle just beneath the hammer’s base.

Thors Hammer in the End

Finally, your stunning version of Thor’s Hammer is complete! However, one small problem remains, are you worthy to lift it?

For more cool project ideas like this, you can check out the DIY projects channel on YouTube. You can also check them out on Yandex Zen as Pro100_DIY.

Photo by DIY projects / CC BY 3.0