Harley Quinn Mallet

Harley Quinn Mallet: This is a large cosplay/halloween mallet made to replicate Harley's. As is it is quite heavy. Keep that in mind if you are making this for small children. We wanted it to be extra large and robust and I think I have achieved that. Please pay attention to the assembly steps so that you don't glue something together before it is needed. It is also a good idea to check fit as much as possible before gluing anything.

1. Start with the End Plates and glue in the large diamonds. (note: I ran my diamonds face down on one of the Galaxy sheets for a sparkle effect.)

    

   2. Glue in all of the small diamonds. Make sure to put the long pins into the front plate before trying to glue on the diamond ring. This will ensure the alignment. I tried to make sure not to get any glue on the pins as I wanted to have the ability to pull them back out if need be before final assembly. Once the two plates are glued together I put clamps around the assembly while it dried to make sure everything stayed flat.

   3. This is the start of the body assembly. Divide the body sections out so that you have a set for the top and a set for the bottom. The inner hex shaft can be used to help with alignment as you assemble. Start with a small pin and connect a single red and black block together. Make sure to align all the seems so that you don't have any overhang.

   4. You can repeat this so that you end up with 4 sets of red and black blocks. 

   5. Glue together two of the sets to make a full bottom set. Make sure to put in short pins. 

   6. Repeat to give you a full bottom and a full top set. These will be aligned together with the dog bones.

   7. Lay in all 4 dog bones and glue the top and bottom halves together.

   8. You can temporarily slide these down over the pins on the end plates to help with alignment. Just be sure that you don't have any excess glue oozing out that will glue the ends on prematurely. 

   9. Once all of the body pieces have dried you can glue the body to the end plates. Be sure that all of the pins are inserted before you put it together.

   10. The handle assembly does not need to be glued but you can if you'd like. I start by screwing the top cap into the Hex shaft. This shaft should slide down in from the top.

   11. Once that top cap and hex shaft are in place you can screw in a handle section. If you are using the textured handles make sure to use the Top-Section version for the first section at the hammer head. After that you can put together as many mid/bottom sections of the textured handles as you want. I made it modular so that you can have the handle as long as you desire. (We did 3 total handle sections) 

   12. Before putting on the bottom cap I pushed a piece of ½" PVC pipe through the entire length of the handle. The pipe should be standard ½" White PVC water pipe. The outside diameter of the pipe I purchased measured 0.840". You may want to print one handle section first and test fit the pipe to make sure it'll work.

   13. After the pipe is installed you can attach the bottom cap.

   Hope you enjoy and have fun!