The final piece for the Thor cosplay, once I made sure everything else worked well, was the helmet. I have always had difficulties finding hats and headbands, because my head is larger than "one size fits all," and it turns out that cosplay helmet patterns have the same limitations. I started with a motorcycle style helmet pattern, but both it and the material I started with (1/4" thick foam covered in Worbla) just didn't work well. It was huge, hard to fit, and heavy, which is a shame because it took many hours getting to that realization point:
