[Tutorial] Super-quick Harley Quinn Mallet

Some time ago I volunteered to join in a costume appearance for fundraising Typhoon Haiyan funds  for charity. I had somehow agreed to costume as Harley Quinn (don't ask, I'm still embarrassed ><) and decided to build her iconic mallet up quick just in case they didn't have any props or other costumey stuff available as it was an extremely short notice thing.

Didn't help that I was busy with other things and ridiculously broke, but it's good to have stock of random supplies in the house...you never know when they'll come in handy!

All in total, the project cost me maybe RM15.

At any rate, this is what I used:

Material:
1 pc 1mm leftoever pvc foam board (something like sintra, but not as expensive)
1 recycled plastic pipe from an older project
4 sets of nuts and bolts
2 appropriately shaped bukkits
Duct tape
Tons of wide masking tape (you'll need a minimum of 2-3 rolls)
Red and black acrylic paint
Matte transparent spraypaint for sealing

Tools:

Soldering iron (because I prefer to melt holes rather than drill them)
Hot glue gun
Screwdriver
Brushes
Markers
Cutter knife (or an x-acto if you have one)
Pliers (optional)

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I started out by using one of the buckets to trace out two circles about as wide as the mouths of the buckets so form the 'lid' of the bucket. I used this bit of extra pvc foam board I had lying around but if you want something cheaper or lighter you could use mounting board or cardboard even. Cut out the two shapes and put them aside.

Next, I cut the edges off the buckets' mouth using a knife and a pair of pliers to help me yank off the more stubborn bits of plastic. I made sure to leave a little bit behind so it's easier to stick the cut shapes to the buckets later down the road. You can omit this step if your buckets don't have a wide 'lip'.Sandpaper it down for safety.

Do the back too!

Careful with the amount of force you use, it's better to twist the plastic off or cut it rather than yank, that can crack the plastic

After that I took the old pipe from an older project (it was a staff) and cut about a foot off to make it short enough for Harley's Mallet. Depending on your construction a PVC pipe might be too soft for use in the long run so I suggest that for longevity you use a wooden stick instead if you can.

I also had to peel off the epoxy clay from the top

I lined up both buckets together and marked where I would put down holes for bolts to hold them together. Note I accidentally broke one of the buckets trying to nail holes with a hammer =\ so I resorted to using a soldering iron for better effect.

accidents happen :(

I also used it to cut out some space to insert the PVC pipe to complete construction. Just do it in a ventilated area if you're melting plastic!

Don't forget to cut some space for your stick

When you're happy with the placement of things, screw in your bolts and pop out your hot glue gun, glue in the pipe with liberal amounts of hot glue as well as around the base of the buckets on the outside for good measure.

Don't worry too much if it's messy, it's likely to be covered by tape in one of the next steps. Duct tape down the stick from the inside for some extra durability.

At this stage you can glue on your bucket 'lids' or do it after you finish your tape. It makes no real difference.

This is roughly what it would look like at this point

Don't forget to cut off any access so the lids are flush with the bucket

Take your tape and tape down your buckets lengthwise. You will have to keep doing this until the entire bucket is coated and it's shape becomes more like that of a mallet, not two buckets glued together hodgepodge.

You can put as many layers as you like, though more is better. The paper tape also helps make it possible to be painted later. Don't forget to press it down till it's snug.

When you're happy with how thick it is, you can then get to painting. I had to do mine indoors so I laid a load of newspaper on the floor and used some plastic bags to protect the chair I was using to prop up the mallet.

The design I used isn't 100% in line with any particular Harley Quinn mallet I've seen (also because I was short of time anyway) but feel free to use any design you see fit. Woman's had a lot of different mallets.

I painted I think maybe 4 layers of red and black. The masking tape will suck up a fair bit of paint on it's own as well, so use liberal amounts but be sure to let each layer of paint dry before smacking on the next. Clumpy paint takes ages to dry.

After it dries completely (it will take awhile, trust me) I hit it with a coat of matte transparent spray paint to seal it up and we were done!

I'm fairly proud of the results considering it was done in a very short amount of time for a ghetto Harley. Hope this tutorial was useful!