Build Thor’s Mighty Helmet In One Afternoon Posted on 8 May 15:11

The Avengers, also known as the most successful superhero franchise in history has finally finished in ‘The End Game.’ As bittersweet as saying goodbye may seem, this Avengers Trilogy also carries the final cameo of Marvel’s creator, the legendary Stan Lee - so watch out for that and marvel at his genius.


Fans are still headed out all over the world for the Avengers screenings, but not many of them will have gone big and made their own Thor Helmet to commemorate the series!

So get to it, my comic loving friend! This helmet is the perfect Avengers party stopper and festival hopping outfit, but it’s also great if you just generally want to feel like the superhero you are.

Unleash the angst of Thor’s mighty thrust of thunder and lighting and GET INTO YOUR SHED to make this. Pronto!


Gather the following set of tools and materials for your Thor helmet making mission...


- Your trusty electric drill and a 9/64" and 1/8" Cobalt or titanium drill bits

- Our own CaNibble Nibbler (you can reduce stainless steel thickness to 1mm with ours)

- An electric grinder or sander with two grades of paper ready to go

- Buffer and white buffing compound and a leather sandbag to use as an armouring swage

- A plastic mallet, a riveting gun, measuring tape and a marker

Basic stuff

Foam padding that’s about half an inch thick, ask for a square 120cms per side.

Some quick grip adhesive - be careful of your fingers here.

Thin cardboard - Manila Folders are useful because of the fold.

Metal stuff

A 15 cm by 15 cm section of thick brass metal. Ask for the 0.06 stock (type 260).

A 30cm by 60cm section of thick stainless steel metal. Ask for the 0.06 stock (type 304).

*Get brass and stainless steel for that cool contrasting look


Three types of rivets by the box.

(1/8" diameter by 1/8" long, 1/8" diameter by 1/4" long and 1/8" diameter by 1/2" long)

Screws, nuts and washers

You’ll also need a dozen screws and wingnuts; we recommend the type  (#6-32)

If you’re safety conscious get some rivet washers too - try the 1/8" diameter size



Before you get started follow this link to make Basic Helmet Frame and make yourself a cardboard,  version of the frame, so you don’t have to ‘mess up’ and repurchase your supplies.

After that’s done simply repeat the process in metal, then you’ll be ready to take the next steps and complete the helmet below. The frame is perhaps the most straightforward bit, so we split the job for you.


- Cut out 4 triangles to form the outside of the helmet's dome.  
- Cut out three circles (To hold your head on the inside and to act as decoration later)

Important note: The size of the triangles will be based on the size of your head so apply the measurements from the basic helmet frame process you did in the link above.

Key Points:

- The triangle’s base should be as long as the circumference of your head.
- Give yourself about 1” to spare for aesthetic purposes
- The final 2 sides of the triangle need to be half the length of the rib.
- Each triangle is going to bulge when it’s hammered - but extra cuts can be made later
- Use a marker to name the pieces left and right, so you don’t get mixed up.


Use the plastic hammer to mould the dome piece into shape with the sandbag as your backing. It’s best to start on the outside and work your way around in a circular pattern into the centre of the piece. Use the marker-drawn triangle as a guide for the bulge.

Finish off with the planishing hammer to smooth things out. Check your triangle piece against the metal of the frame to make sure it fits flush; you may need a couple of attempts to get this right.


Place each dome piece inside the frame and use your Beverly shears to trim them, so they fit flush. Use the marker to help guide your cuts.


This is where your helmet becomes a helmet! Line up the pieces nicely inside the frame then use the temp rivets and wingnuts to attach them. We recommend three holes (one in each corner of the triangle) for stability. Trim and hammer out any bits that aren’t fitting well.


Now it’s time to make things permanent. First polish everything then one by one replace each of the old rivets you had put in with the permanent fixtures. Don’t forget to add stability with rivets evenly placed around the band of the helmet, bolting the dome to the frame.


Cut a circle from the brass plating and beat it into a shallow dome to decorate the top of the helmet and cover any mistakes. Halve another brass circle and rivet the two half shapes to the front and back of the helmet for style and total superhero badassery.


Finally, use the padding for the inside of the helmet by cutting out half circles and glueing them inside. Give the glue time to set before you try it on for size then add another layer if you need more padding. Easy!