How To Make A Thor Helmet

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I’m making a Thor Helmet for my son for Halloween. I had planned on making this in time for Dragon*Con, but Dragon*Con is not until the end of August and I’m not sure I’ll be able to complete all the steps before then. Also, we’re going to be out of town the weekend of Dragon*Con and so we would miss it anyway.

So, I’m going to go ahead and write up all the steps here and post pictures as I progress through them. If you have any questions or comments, feel free to share them.

So, let’s get started. First up, a list of materials:

I’ve made a Thor helmet. It’s pretty good!

This is a blog post about how I made it. If you want to make one too, it’s not hard if you have the right tools and materials.

It’s a Halloween costume, so I can’t have spent too much on it. I guess maybe $200 in total?

How To Make A Thor Helmet

As seen at SDCC 2014!

Note: This is my first Instructable and I will be showing you how to create a 3d printed Thor Helmet that can be worn.

Materials:

Software

– Tinkercad.com (or your favorite 3D modeling software)

This article will cover how to make a Thor helmet. The first step is to measure your head. You’ll need the circumference of your head, the width of your head at the forehead (approximately), and the distance between your ears. Once you have those measurements, use them to create a template out of heavy paper.

Next, you’ll want to cut the cardboard into strips and form it over your template. Make sure there are no creases in the cardboard when you apply it to the template. Glue the strips together using wood glue or superglue, then repeat that process for the back piece of cardboard. After you’ve done that, apply masking tape to all of the edges where pieces meet.

Once everything is dried, sand down any rough spots with fine grit sandpaper or an electric sander. Next up is painting! Get some spray paint in whatever color you want (I used metallic silver because I like shiny things) and paint both sides of each piece before assembling them together with hot glue and/or superglue. If things get messy during this step just use more masking tape on top of it all – it’s better than cleaning up drips later on!

If you want to make a Thor helmet, you’re in the right place!

I made this helmet for Halloween 2013, and I’ve gotten so many questions about it that I figured it was time to write up a tutorial. Just to let you know, though: this costume is a lot of work. It took me around 20 hours to make everything, and I had some help from my boyfriend with the helmet part.

I’m no professional when it comes to costumes or cosplay, but I think my costume turned out pretty well. So if you have no idea what you’re doing, but are willing to put in the time and effort to learn as you go, this tutorial is just for you!

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