How to Make a DC Harley Quinn: "Mallet" Carrying Case
Introduction: How to Make a DC Harley Quinn: "Mallet" Carrying Case
Hello Puddin', we're back for round two with a different variation of my original Harley Quinn Mallet tutorial. For the 2020 Chicago Comic and Entertainment Expo, our group wanted a DC Batman Theme. The only problem was, we had a baby with us this year... Well, with having a baby on board, we needed to figure out inventive ways to carry a baby's things such as diapers, wipes, formula, etc. without having to use a bag and distract from the costumes. I had some brainstorming to do, but I figured out that I could make hollow mallet to function as a carrying case that our Harley Quinn Cosplayer could use as a prop. Let's get started!
Supplies
- EVA foam (roll, and thick tile mat)
- Strong mini magnets
- large popcorn tin
- contact cement or Hot Glue
-exacto knife
- paper
-caulk
-heat gun
-dremel will cutting attachment and sanding attachment
-PVC pipe
- PVC 3 way adapter
- 2 PVC adapters
-PVC end cap
- hockey grip tape
-Measuring tape
-soldering iron
-Acrylic paint
-Modge podge
-clear sealer
Step 1: Reference Pictures
Before I ever start ANY costume or prop, I look up a ton of reference photos from various sources and put it in a folder. The more pictures from different angles, the better. Look up:
1. Actual photos of the character/prop from its source (movies, comics, action figure, etc)
2. Cosplay pictures. You can see what has been done, what you like, what you don't like, how to improve on a design. You can also start getting an idea of different poses you think you'd like to do.
3. I start looking at art work. I usually look up things via google images, deviant art, tumblr, etc. This way, you can see different renditions of a character through a new perspective and once again, start thinking about what you like, don't like, etc.
4. Use your own imagination. Think about what you want, how to make it your own original design, what are some tricks you think you'd like to incorporate.. perhaps you want to try out a new technique with this build, etc
5. 348
If you can draw, I sometimes will take all my reference sources and start drawing out my own design.
For this mallet, i wanted to give it a some new coloring and a little bit of a different shape for the head. I liked the the idea of having interchanging black and red colors to in and also liked the idea of painting a face on one side.
Step 2: Sides of the Mallet
You will need to figure out the dimensions of mallet. You are essentially making a cylinder so you need two circles and a body. However, the circles have to be the diameter of the popcorn lid. So do the following.
1) Trace the lid of your popcorn can onto a piece of paper. From there, use that piece of paper and cut out those two circles from thick EVA foam (pic 1)
2) I wanted to make the mallet look like a sawed off log, so i first some wavey lines into each circle to resemble the "grain" of a wood log. You are not trying to cut through the layer of PVC, but you are just creating a groove in it. (pic 2)
3. Use your heating gun and heat up those cut lines. They will open up and create a nice wood pattern for you. (pic 2)
4. take your soldering iron and burn a few tiny holes on the backside of 1 of your circles. As these hole will be for gluing in your magnets, do not make them too large. I used 5 mini magnets and then contact cemented them inside each hole. You only have to do this to one circle, as the other will be permanently glued in as the bottom of the mallet head.(pic 3)
Step 3: Internal Skeleton
Now that you have your side circles, you can start to figure out how big the mallet should be.
1. Start cutting out your PVC skeleton to be in proportion to your circles. You basically need to figure out how LONG you want your mallet head to be. I eyeball it and figure out how long it should be based on the size of the circles.
2. Your 1 side pie of PVC will go onto the bottom of the "T" PVC joint.. This PVC side piece will sit in the center of your EVA foam circle you made in the last step. 276