Making the Perfect Mallet

The character uses a baseball bat in Suicide Squad, but when Trinity decided to cosplay as Harley Quinn for Anime Midwest, she wanted a mallet. Not just any mallet, a big honking mallet that a strong man would swing around with glee and wild abandon.

Unfortunately, Trinity weighs slightly more than a strong man could bench press with one hand. Building this prop required materials that would be large enough to make a statement and light enough for a wisp of teenager to comfortably carry for a few hours around a convention floor.

We searched the Internet for help and found http://www.instructables.com/id/HARLEY-QUINN-HAMMER/. We took it from there ourselves.

Materials:

Building this prop required:

  • 1&1/2″ PVC pipe cut to a six-foot length
  • Two 1&1/2″ PVC pipe caps
  • 1/2″ wooden dowel cut into two six-inch lengths
  • 12″ cylinder concrete form cut to four feet
  • Box cutter
  • Duct tape
  • Drill with a 1/2″ bit
  • Glue
  • Tape measure
  • Paint and brushes

The Plans

To build the mallet:

  • Drill two 1/2″ holes through the PVC pipe, at one end, just far enough apart to fit inside the concrete form;
  • Cut two 1&1/2″  holes in the center of concrete form, opposite each other;
  • Insert the PVC pipe through the holes in the concrete form;
  • Thread the dowels through the PVC. Secure the dowels to the interior of the concrete form with glue and duct tape;
  • Cover the ends of concrete form with duct  tape;
  • Hammer the PVC caps onto the ends of the pipe; and
  • Paint.

Building the Mallet, in Pictures!

The Plans

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