Making Thor's Hammer

Started with a big block of forged aluminum 7075 T7.

Laying out the line of where we will cut it and have our guide in place.

Starting the profile curves of the handle.

Every night we made a big mess.

A look at the curve of handle.

This is one of the polished rings from the handle right after it was machined out.

Another look at the ring.

The plate that held the rings.

This was the spacers for the handle which were later painted brown.

Look at that nice finish.

The block is 11" tall. Water bottle for scale, couldn't find a banana.

This is how we set up for the chamfer on the ends of the hammer. We made them to 20 degrees.

One side has been completed her.

All end angles have been finished. the block is 11"x5"x4"

Putting the second angle on the block, this one was at 45 degrees.

Boring out the center for the handle.

This was the first time we put the completed handle on the hammer head.

Here is the handle all set and ready to be installed.

Final product. We sanded it up to 800 grit.

Whoever holds this hammer if he be worthy. Shall posses the power of... CMSgt Orrell.

This was the chiefs going away gift.

Chief stripes as the sop cap.

A close look at the pommel.

Bonus look at Captain America's Shield being made. I didn't make this one but another person did at the same time we were making the hammer.

The back side was cut out to save weight.

Here's a look at the machined out product as we were sanding it. It was 18" in diameter and was made out of 2" stock.

The back side.

Final painted product.