Sabaton being just a fancy word for foot armor, and Thor definitely needs foot armor. I had a pair of black boots with about a 1" heel that I figured would work well as a base, and downloaded this pattern to get a general idea of how sabatons work. Obviously, I couldn't follow it perfectly, since it's made for a non-heeled shoe, but it made a good first attempt. Several tweaks later, I felt I had something good enough to cut out of foam:
A functional difficulty for shoe armor is that it has to flex with your foot. A breastplate or bracer doesn't need to move, but if you make fixed joints on a shoe, you're not going to go far. I used random bits of wire to test the pattern pieces out, but that wasn't strong or pretty enough for a final go. After some hunting, I found screw rivets (aka Chicago screws), primarily made for binding books, but conveniently the right size for, say, sabaton joints. With the screw side on the interior, it looks a lot like rivets you'd see on actual armor. I covered all the pieces with Worbla, poked (a lot of) holes in them at what felt like the right points, and had a pretty decent, functional piece of armor.
A functional difficulty for shoe armor is that it has to flex with your foot. A breastplate or bracer doesn't need to move, but if you make fixed joints on a shoe, you're not going to go far. I used random bits of wire to test the pattern pieces out, but that wasn't strong or pretty enough for a final go. After some hunting, I found screw rivets (aka Chicago screws), primarily made for binding books, but conveniently the right size for, say, sabaton joints. With the screw side on the interior, it looks a lot like rivets you'd see on actual armor. I covered all the pieces with Worbla, poked (a lot of) holes in them at what felt like the right points, and had a pretty decent, functional piece of armor.