A LION'S ROAR ENTERTAINMENT PRODUCTION
FATHERS OF THE DARK Knight
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  • CAST & CREW
    • Roberto Williams
    • Zach Karem
    • Ezekiel Jackson
    • Mark Anthony Montalvo
    • H. Max Rosenthal
    • Kendra Avans
    • Russell Mahrt
    • Ryan Dempsey
    • Aaron David Kapner
    • David Estrada
    • Jamie Soltis
    • Gyomara Phillips
    • Nick Byrne
    • Micah Henning
    • Allison Rapsas
    • Rene Antonio Rivera
    • Anthony Cuevas
    • Alaja Desilva
    • Charles Grant
    • Doreen Hunter
    • David Bicknell
    • Henchmen & Hoodlums
  • PRODUCTION DESIGNS
    • Gotham City Rooftop
    • Bob Kane's Apartment
    • The Batcave
    • The Iceberg Lounge
    • Police Headquarters Rooftop
    • Wayne Manor Study
    • The Batmobile
    • The Riddler's Warehouse Hideout
    • The Bat-Signal
    • Globe Building Rooftop
    • Gotham City Back Alley
    • Commissioner Gordon's Office
  • COSTUME & PROPS CONSTRUCTION
    • Bat Gloves
    • Cowls
    • The Batman's Cape
    • The Batman's Utility Belt
    • The Batman's Chest Emblem Shield
    • Batgirl's Utility Belt
    • Robin's Vest Tunic
    • Robin's Chain-Mail Shorts
    • Robin's Utility Belt
    • Robin's Pixie Boots
    • The Batman & Robin Costumes
    • Bat-a-Rangs
    • The Riddler's Hat and Face Mask
    • The Riddler's Belt
    • The Riddler's Walking Cane
    • The Riddler's Shoes
    • Harley Quinn's Giant Mallet
    • Bob Kane's Candlestick Telephone
    • Harely Quinn's Bazooka
    • BAT ROD PUPPET
  • BEHIND THE SCENES
    • CASTING CALL
    • Publicity Photo Shoots
    • Rehearsals / Costume Fittings / Make Up Tests
    • Lighting Tests: Robin The Boy Wonder
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designing harley quinn's giant mallet weapon

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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

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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.

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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

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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
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Finished mallet prop in use by Harley Quinn

Transport And Storage: Harley's Mallet and pop cork gun

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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!

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All images and content copyright
“Fathers Of The Dark Knight”  © 2011-2013
Do not use any image without permission.

Batman and related characters are the property of DC Comics and Warner Bros. Entertainment.  “Fathers of the Dark Knight” is a non-profit,  student cosplay stage production that is in no way sponsored, approved, endorsed, nor licensed by DC Comics, Warner Bros. or any of their affiliates.