Knuckle Dusters / Batarang

Hi Everyone!

So here we have a neat little Batarang that I made to show the versatility of the Dark Knight's go to weapon. Its incredibly easy to make and makes for quite the addition to the utility belt.

This is my first Instructable so please feel free to comment and ask questions where and whenever you feel there is lack of information.

Materials:

Tools

- Jigsaw

- Large drill bit(s)

- Sand paper (80, 100 and 500 grit)

- Metal file

Other Materials

- Spray paint (any would do just fine)

- Plexiglass (I use lexan, it comes in 14 x 10)

Step 1: Step 1: Making a Template

This is where your creativity shines through, just make sure to make said creativity symmetrical and comfortable for yourself. I find it helps to draw the shape of the knuckle duster first, then design the shape of a batarang around it. Fold in half down the center to see if its symmetrical or use a ruler to be precise. Measure twice, cut once.

Step 2: Step 2: Sanding & Shaping

Now comes the tedious part, youre gonna want to bevel the edges, to do so, I suggest starting with the metal file, use it on an angle and work away from the center. Once you have beveled edges, you want to make sure the surface is even and uniform, to do this you can start with either the 60 or 80 grit sandpaper, and gradually work up to 100 and once youre sure its exactly the way you want it to be, give it a wet sanding with the 500 grit for a nice finish.

Notes: Always indicate for yourself what needs to be changed, I always use a marker and different angles of lighting to check for imperfections.

Step 3: Step 3: Paint

This is quite an easy step, just follow the instructions on the spraycan. Find a well ventilated space, something to hang this batarang up with, and stay 12-15inches away when you spray paint. Give it two coats.

And there you have it. Also, innovate and experiment with your materials and see the potential in design. For instance, you can make this out of metal using sheet metal and it would still be the same process.

Step 4: Step 4: Test the Waters.

Make more. Innovate. Change things up. I know you'll do great things. Just be safe and responsible.