Thor Love & Thunder Armor
This build thread will cover the creation of Thor’s new armor from the Love & Thunder film. When the project was started, reference images were scarce - in fact, the project was completed before the first trailer was released - so the entire project was done with these three images.
As always, the pattern was the first step. I decided to use the pattern I developed for my Etsy shop for the base. I created a mockup in a similar weight and thickness to the expected finished product and sent it off to the client for a fitting. Once the fit was confirmed, I could create a muslin version and sketch the vest details.
I began with the main torso. Using the muslin with the details, I built the vest out of metallic blue and black faux leather backed with headliner foam. In some areas, such as the chest, abs, and sides, 2mm EVA foam was sandwiched between the materials and sewn down to create the depth needed when the “armor” details were added.
A large segment of stretch material extends below the shoulder blades and covers the lower back. This piece will be covered by the cape, allowing for a better range of motion and breathability at a point where most men sweat the most.
At this point, I created the shoulder piece and outer collar. I also began cleaning up the templates for the armor pieces and the discs.
Next, the lower parts of the vest were built. The front, side, and back tabs were all constructed by layering headliner foam, 2mm EVA foam, and metallic blue and back faux leather. The back panel was attached with snaps and was made removable to accommodate the zipper.
The shoulder/outer collar was finished, and the inner collar with the red detail was created as a separate piece worn under the vest. Here is the complete vest and collar.
While the vest was underway, the discs were being fabricated by superdaftbros. I created flat vector templates in the correct scale to fit the vest, and he made 3D files from them. Those files were printed in clear resin so that, once painted, lights could be installed in the back and show through specific details.
After printing and painting the discs, I created the light effects using LED fairy lights with small battery packs. Each disc had a light pack, and each set of lights was mounted to an EVA foam disc and then glued to the back.
The discs are secured to the vest with industrial-strength velcro. The vest has slots punched into it for the battery packs to slip through to the inside.
I moved on to the accessories next. I created templates for the gauntlets and boots and cleaned them on paper.
For the gauntlets, I built the front pieces out of layered 2mm EVA foam covered in metallic blue faux leather and used a cording foot to sew down the details. I then finished all the edges, added the painted foam details, and built the backs. The backs of the gauntlets were constructed from headliner foam covered with black faux leather and blue and red details. They were finished with separating zippers on the backs of the arms.
The boots were next. I based the boots on my fitted boot pattern and modified it for the details needed.
The upper parts of the boots were created as separate pieces using the same techniques of layering foam and faux leather that I’ve used up to this point. They close with separating zippers up the back and have foam details like the vest and gauntlets.
I then created the ‘shoe’ parts of the boots to go over existing mesh running shoes that fit under the tops. Having the upper parts of the boots and the ‘shoes’ separate enables more effortless dressing and a better range of movement without worrying about overstressing any part of the boot. This is the same approach as the Night Monkey boots.
To finish off the costume, the pants were built with faux leather accents and stretch material in the crotch, inner thighs, and below the knees.
The cape was also built to hold its folds and attach to the vest with Chicago screws for stability - a similar technique to the one I used for Dr Doom.
And at last, the final costume in the wild!
