Getting props right can be just as important as nailing the costume. What would Thor be without Mjölnir by his side? The site Blind Squirrel Props offers plenty of prop tutorials and has one all about fashioning Thor’s hammer from wood and vinyl. The materials make the hammer heavy, but that’s sort of appropriate. Here are the basics (several photos are available):

I cut sheets of 3/4″ MDF to laminate into a 9″ x 4″ x 6″ hammer head. I drilled holes through the centers of all sheets.
The bevels of the hammer were cut by tilting the table saw blade 45 degrees.
The porous edges of the MDF were coated in Bondo spot filler and sanded smooth. I then gave it several coats of automotive sandable primer. The “cap” was cut from a piece of plywood and given a bevel. The whole thing was sprayed with more primer coats and then finally a Krylon Aluminum.
For the handle, I decided to use an old tree stake that I had sitting around.
I had trouble finding leather strapping in the right thickness or width but found a tan vinyl that I could cut myself. The grip was wrapped with four 60″ straps in a tight overlapping pattern.

Read more at Blind Squirrel.