To forge a honking big metal hammer what you'd need is a forge, an anvil, smaller hammers to make the bigger hammer, Time, patience, and some steel
1. forge the handle out of I'd guess some bar stock or if you want to get fancy some oval stock if you can find it.
a. In order to do this you would take your oval stock and heat it in the forge until it glows a cherry red then beat
metal into the shape you want using your hammers and the anvil. You will probably have to reheat the metal
several times while in this process
B. When making this handle make it so the end you will insert into the hammer is actually a half inch or so too
long so that a nub will be sticking out of the top of the hammer. You'll actually use this nub to secure the
head and the handle together.
C. Once you have the handle in the shape you want it put it on a metal lathe and turn down section that is
going to be inserted into hammer head so it is a standardized size that you can make with a drill bit and at
least an 1/8 of an inch less in diameter than the rest of the handle. (Ideally you will want the part you grip
to be an oval and the part you put into the hammer head to be circular.) So now you have a handle with an
oval shaped grip shaft and a circular end for sticking into the hammer head which will extend about a half
inch above the top of the hammer head.
D. Since you have softened the metal appreciably by working it you might want to heat treat the handle so it will resist bending once you have the
hammer built, do not heat treat the nub that will stick up above the top of
of the hammer because we will be pounding this nub down to seat the hammer head to the shaft.
2. Forge the hammer head.... this will be difficult you will need to start with mutliple pieces of steel and forge them all together into a big giant
block. This block will be heavy and hard to work with.
a. I'd go about this by using sheets of 1/4 inch or 1/2 inch steel and heating two at a time which I"d then attempt to fold around each other then
hammer the hell out of it until it makes one piece out of the two.
b. After you've made I'd say a good half a dozen of these super sheets I'd combine two of the super sheets
again folding and hammering until it's one piece of steel not two. At this point you're still not worrying about
the shape all that much you are just trying to get a large enough hunk of metal to build the hammer head
C. After you've combined all the super sheets into one massive block you can now begin to shape the hammer
head. Again you will be heating it up and pounding the snot out of it until it looks like a hammer head which
can take anywhere from a few hours to a couple days.
D. Take a drill press and drill a hole through the center of your hammer head that matches the size you turned
the hammer head shaft to.
E. Insert the hammer shaft into the hammer head and then heat the 1/2 inch extension beyond the top of the
hammer head in the forge and pound it down so that it secures the hammer head to the shaft.
And with that you will have a Thor like hammer. I doubt you'll be able to lift it and swing it since it'll be pretty darn heavy but it'll probably
look pretty cool