I have always wanted to make this project but have put it of for ages until i watched the Dark Knight with my friend and saw the Batarangs in action and wanted to make it again so here it is. This project isn't too hard and should be a great project for any skill level. Click here for the video
Step 1: Template
So to start you want to print of a template of a Batarang cut it out and ether glue it on to the steel but what i would surest is to mark it onto the steel using a permeant marker as under the heat of the grinder it maintains the mark. Just search batman logos.
Step 2: Cutting the Batarang Out.
To cut the Batarang out I use an angle grinder because it is a lot quicker than a hack saw, but if you don't have an angle grinder a hack saw will still work but you might want to use a weaker metal to make cutting easier. METAL CHOICE. The advantage of using high carbon steel is that when it comes to heat treating you batarang it comes out with a very hard point. If you chose to use aluminium don't heat treat it as it can melt the batarang. Aluminium can only be used as a prop or for soft targets. With mild steel you can heat treat but its still not going to come out with a sharp edge so there is less point, they are still fun to use against cardboard targets though. CUTTING TECHNIQUE. When cutting a curve you can use a smaller disk (one that has been worn down) and lay the angle grinder more horizontal and rolling the cut of disk. To get into tight spots you can do a series of cross cuts taking out little bits at a time. If you need more help with angle grinders you can look at this youtube video
Step 3: Refining the Profile
TIPS. When Refining the Profile it helps to have a container of water next to you to keep the temperature down so you don't burn yourself, also it makes sure the metal doesn't over heat and ruin the steel. It pays to leave a little but of extra steel on the edge so that you don't over grind. Another tip is to print of another copy of the batarang to compare your steel batarang with so that you can be as accurate as possible. Some times I use a permanent marker and mark the spots I need to grind of so that you can see what you are working on as you are grinding.
Step 4: Shaping the Bat's Head
To start the shaping of the bat's head I start by marking on the head with a marker the parts that need grinding. With my angle grinder i proceed to shape the head carefully. After that is done I clamp it up and use hand files to shape the head. TIP If you are doing a lot of projects like this you can buy a set of files that include a round, half round, square, triangle and flat for only about $12 NZD.
Step 5: Sanding
The point of sanding is that it makes it look a lot better and it also makes it easier for the paint to stick if you choice to do that. I started with a 180 grit sand paper and ended up with a 212 grit. For me there is no point to go any finer as i am painting it.
Step 6: Bevels
The Bevel on your batarang can be as steep or as shallow as you want them to be. I have gone in-between. To put the bevels in i use the grinder but you could just as easily use a file.
Step 7: Heat Treat
For heat treat make sure that your steel can withstand enough heat and not burn or curl over at the end. This means that you shouldn't use aluminium or any thing like that as they are only for props and other things like that. What you do for a heat treat is you heat up ether a fire place, a forge or a gas torch so that you can get your metal a cherry red colour. When you are at this stage drop it into quenching oil if you are after a great finnish but if you don't have any oil (like me) you can use warm water. To get maximum heat out of your fire try blowing on it with a hair drier or a fan but if you have a fire place a trick I use. After you put your blade in also put in scrunched up news paper this burns quickly and also draws in a lot of air which feeds the fire turning your blade red.
Step 8: Tempering
To temper all you have to do is put your batarang in an oven for 3 hours or so at 180c this protects it from shattering after heat treat.
Step 9: Prepping for Spray Paint
All you have to do to prep for spray paint is sand the batarang so that the paint can adhere to the surface. But if you don't have any spray paint you can just sharpen the edges and it looks great it looks like the first photo. If not continue onto the next step.
Step 10: Painting
For painting it comes down to personal preference as to what colour you want and all that. But what I did was two coats on ether side with rust-oleum black gloss. The only thing with spray paint is the read the can and know what temperature to spray at and what distance away from your work thank your sweet.
Step 11: Final Step
All you have to do is re-grind the bevels on the batarang and you are done.
Thanks for looking this far if you think there is any thing that i should have included in this insturctable that i didn't or any thing that i should put in for the next one please tell me thanks.Also CHECK OUT my channel Double Edged here