designing harley quinn's giant mallet weapon
The design for Harley Quinn's giant mallet Prop is loosely based on the "barrel head" design first introduced in Batman: The Animated Series. Production designs by Roberto Williams
fabricating harley quinn's giant mallet weapon
A 6-foot long , 1-1/4 inch in diameter curtain rod served as the basis for the mallet prop. The rod was cut down to 55 inches.
As an inside joke, Production Designer Roberto Williams selected a pair of 5 1/2 - inch long Jackhammer Anderson Handlebar Grips for Harley's weapon. These are the handle grips commonly used on HARLEY (as in "Quinn") motorcycles.
The mallet head
After daily searches on-line for over 2 months, this vintage Styrofoam ice cooler decoration (in the shape of a wine barrel) was finally located on Ebay from a seller who was liquidating the items from his pub. The prop was sculpted with a very nice simulated wood grain texture, and was perfectly light-weight enough to be handled by any actress playing Harley Quinn. However it would require quite a bit of work:
The 'Hiram Walker's TEN HIGH Bourbon" decal Graphics would have to carefully be removed with sandpaper.
The black bands molded onto the barrel's surface would need to be carefully shaved away with a razor, and the established wood grain pattern would need to be continued over the areas previously occupied by the bands.
The hand hold indents on the sides of the barrel would all have to be filled and then sculpted over with a continuation of the wood grain pattern.
The inside of the barrell decoration would need to be filled with polyurethane foam, so as to strengthen it by converting it into a sold prop.
The 'Hiram Walker's TEN HIGH Bourbon" decal Graphics would have to carefully be removed with sandpaper.
The black bands molded onto the barrel's surface would need to be carefully shaved away with a razor, and the established wood grain pattern would need to be continued over the areas previously occupied by the bands.
The hand hold indents on the sides of the barrel would all have to be filled and then sculpted over with a continuation of the wood grain pattern.
The inside of the barrell decoration would need to be filled with polyurethane foam, so as to strengthen it by converting it into a sold prop.
Finished mallet prop in use by Harley Quinn
Transport And Storage: Harley's Mallet and pop cork gun
Custom-made boxes for the storage and transport of all costume and prop pieces were obtained from The Custom Box Company of Flower Mound, Texas. The box for Harley Quinn's mallet weapon is the size of a coffee table!
