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Batarang from "Arkham Asylum" Game

by spookylean on August 15, 2010

Table of Contents

License: Attribution Non-commercial Share Alike (by-nc-sa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Intro: Batarang from "Arkham Asylum" Game . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1: Tools and Shopping List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 2: Cutting the Plexiglass to Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 3: Shaping the Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 4: Beveling the Wing Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5: Making the Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 6: Placing the Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 7: Finishing Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
License: Attribution Non-commercial Share Alike (by-nc-sa)

Intro: Batarang from "Arkham Asylum" Game

This is an instructable for making a replica of the batarang seen in the game “Batman: Arkham Asylum.” I wanted a batarang that unfolded with an action similar that
that in the game. Not counting the cost of the tools, which I had already, and the paint (ditto), the entire project cost me about $17 and took perhaps 10 hours.

step 1: Tools and Shopping List

I decided to make this prototype batarang out of Plexiglass, because a) it is easy to work b) it has no grain and doesn’t splinter or chip c) it is transparent, which helps
with aligning the pieces d) it takes a metallic paint better than wood, and, finally, e) I didn’t have access to a metal-cutting bandsaw. Needless to say, you won’t be
knocking any thugs unconscious with this one. You probably won’t be throwing it anywhere, either, unless you want to see your hard work shatter into bits.

Shopping list:

.093”x11”x14” Lexan (or Plexiglass) sheet

Furniture joint connector nut, ¼”-20 thread
¼” x 3/8 flathead machine screw
four neodymium disc magnets .47” x .11” (12mm x 3mm)

Tools required:

Coping saw
Straight and curved files
Power drill
Various drill bits, including a ½” spade woodborer
“Liquid Nails” clear silicone adhesive
Cyanoacrylate superglue
Two part epoxy resin
Sandpaper

step 2: Cutting the Plexiglass to Shape

The Lexan sheet was too thin, so the first thing I did was cut it in half across the long axis and glue both pieces together, resulting in a sheet 11” x 7” x 0.186” thick. A
word on the glue: I used three types of glue in the project, Liquid Nails silicone adhesive, two part epoxy resin, and cyanoacrylate superglue. There’s a lot of prying
stress put on the various pieces of the batarang while it is being filed into shape, and the Liquid Nails quits after a while. This doesn’t matter, as I had to pull it apart
several times to correct mistakes. When everything was ready to be finally glued, I used cyanoacrylate which is notoriously unforgiving of mistakes. For gluing these two
sheets together, the superglue is preferable.

I found an image of the batarang on the internet, and printed it out as a template at the size I wanted. Because I was going to have a hinged batarang, I only used one
wing as the template for both halves, which helps with symmetry. I then cut out the three pieces of the ‘rang with a coping saw. If you are going to do the cutting with a
bandsaw, make sure you have good dust extraction – unlike sawdust, plexiglass dust can get hot enough to catch fire.

I call the three pieces ‘the fixed wing,’ the ‘pivoting wing,’ and ‘the back piece.’ The fixed wing and the back piece will join together to make the 'back assembly,' the
half of the batarang you hold in your hand. This is a right-handed batarang, but you can easily reverse the pieces for a left-handed one. The fixed wing is just the pivoting
http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
wing with the circular axis removed, and the back piece is just the center of the batarang with a bit of overlap where the magnets will be placed.

Image Notes
1. The pivoting wing
2. The fixed wing
3. The back piece
4. The cardboard template all three pieces are based on.

step 3: Shaping the Wings

The next step, after smoothing off the rough edges with a file to make them prettier and easier to handle, is to make the three pieces true to each other. The easiest way
to do this is to make the backing piece as perfect and symmetrical as possible, decide which way up it will face, and base the other two wings off that. Mark the center of
the back piece with a dot.

First off, try and align the pivoting wing with the backpiece, and correct the pivoting wing where it needs it, using a file. Once the places where they overlap matched up,
mark the pivoting wing with a dot that overlaps the back piece dot. Hold the pivoting wing in place with a small clamp or clothespin and shape the fixed wing until all three
pieces fit together neatly.

Image Notes
1. All three pieces neatly trued (but not glued) together

Image Notes
1. Truing up the pivoting wing and the back piece

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
step 4: Beveling the Wing Edges
Now it is time to bevel the chisel edge of the wing blades. Mark a line that runs parallel to the edge of the wing, then, using a flat file, form the blade. Because you are
using two sheets of plexiglass glued together, it’s easy to mark your progress by the center join (but because you are not making an actual working blade, you don’t
need to file all the way down to the center of the wing thickness). Spend some time on this: a good consistent bevel is important to the final look of the batarang, although
paint will help if you can’t manage it.

When this is done you can glue the back piece to the fixed wing to form the back assembly, the half of the batarang you hold in your hand (assuming you are right
handed). When the glue dries, do a final filing and sanding of the places they overlap to make them completely true.

Image Notes
1. Unfinished bevel
2. Finished bevel

step 5: Making the Axle

Now make the axle of the batarang. Tape the two wings together in the final position, and drill a pilot hole though the center. Separate the wings again, and drill a hole in
the pivoting wing just large enough to accept the machine screw fairly tightly (15/64” was right for me). Then through the fixed wing assembly drill a hole large enough to
accept the furniture joint connector (3/8” was perfect). The connector needs to pivot smoothly but not be loose.

I then countersunk the machine screw hole in the pivoting wing, and, using the large 3/8” bit, recessed the other side of the hole to accept a small portion of the furniture
connector. This was because the furniture connector was a little too long and I didn’t want the wing to be loose when folded up. I could also have ground down the
connector a bit but this seemed easier, and it worked fine.

Image Notes Image Notes

1. The furniture connector coming through the back assembly 1. It's a little hard to see, but this is the tiny recess to accept some of the furniture
connector on the reverse side of the pivot wing.
2. The machine screw in the pivoting wing
3. Magnets epoxied in place (step 6)
4. Magnets epoxied in place (step six)

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
step 6: Placing the Magnets
Now to place the magnets that will hold the batarang in place when it is opened. Tape the batarang together in its final position, and drill a pilot hold through the part
where the backing piece and the pivoting wing overlap. Exact placement of this hole is not critical, just make sure it's not too close to any of the edges. Then widen this
hole with the ½” woodborer bit. I used a ½” because my magnets were just a tiny bit smaller than that, but if you use different magnets from me, adapt the hole to fit.
Using tape to separate the holes in the wings (so you don’t glue the wings together), glue the magnets in place. I used two per wing. Make sure you align the
North/South correctly so that the wing will not repel itself! The magnets won’t take a lot of stress, so I used two part epoxy resin for this job, which also filled the gap
around the magnets.

Image Notes
1. Magnets in the pivoting wing (back assembly magnets are underneath, kept separate by the tape while gluing)
2. Back assembly

step 7: Finishing Up
You can now assemble the batarang. I glued a little plastic widget over the machine screw head to cover it. You can still take the batarang apart by unscrewing the
furniture connector from the rear. This is why you want to machine screw to be fairly tightly in place.

When this is done, you are almost finished! All it needs is any final shaping and filing, a bit of sanding of the edges, and you are ready to paint. I used a satin black spray
paint specifically for plastic, and bronze model paint for the wing bevels.

Image Notes
1. Finished and ready to paint

Image Notes
1. Reverse of the batarang, showing the back piece and the furniture connector

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
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Comments
25 comments Add Comment

Neotron says: Aug 22, 2010. 4:12 PM REPLY

So I would like to know how you got your design or where. I make knifes all the time for friends and family and I would love to build this with a locking device
out of steel. If you can guide me in directions to template that would be great. Also great instructable I love BATMAN

spookylean says: Aug 22, 2010. 9:50 PM REPLY

It's at the bottom of page two. If you make one I'd love to see pics.

Blonde Chicken says: Aug 22, 2010. 3:14 PM REPLY

That is so amazing!!! I've always loved batman. I'm so going to try this!!

HomemadeHonor says: Aug 22, 2010. 2:43 PM REPLY

If you don't try throwing it and post a vid, I'll make one and find you.

nyquilpillz says: Aug 22, 2010. 11:21 AM REPLY

what are the chances of getting a link to a full sizes stencil of what you used?? i would make my own but honestly yours looks so good i would rather use
yours ha

spookylean says: Aug 22, 2010. 12:34 PM REPLY

It's a little hard to see, but I posted a stencil with a scale bar at the bottom of step two. You should be able to print that out full size.

nyquilpillz says: Aug 22, 2010. 1:02 PM REPLY

oh wow yeah.. didnt have my contacts in earlier.. sweet thanks! im heading out now to get the material needed! im so excited!! thanks! haha

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
 TecDroiD says: Aug 22, 2010. 12:30 PM REPLY
does it really work like a boomerang? i'd like to see some video :)

funkybassman105 says: Aug 15, 2010. 6:27 PM REPLY

lexan and plexiglass arent the same thing.

spookylean says: Aug 15, 2010. 6:38 PM REPLY

You're right. Plexiglass and Lexan are both trademarks. Either transparent thermoplastic glass substitute should work...

manouttatime says: Aug 17, 2010. 6:52 PM REPLY

Actually, Plexiglas is the trademark. Plexiglas is acrylic sheeting and Lexan is polycarbonate sheeting if you want the generic names. These come in
handy when asking for the stuff at Lowes and all they carry is Optix brand acrylic.

brandon9271 says: Aug 22, 2010. 7:42 AM REPLY

polycarbonate doesn't shatter either.. at least not easily. So you could throw that bad boy :)

seltzer10 says: Aug 20, 2010. 9:33 PM REPLY

dude i like it you should make steel one!

ninj4boy00 says: Aug 20, 2010. 10:55 AM REPLY

How did you cut the plexiglass to make it so round?? how did you cut it.. and where did you find the template ?? pm me back =)

spookylean says: Aug 20, 2010. 2:21 PM REPLY

I cut the plexiglass with a coping saw - a handsaw with a very thin blade used to cut intricate shapes. http://en.wikipedia.org/wiki/Coping_saw This step
by far required the most patience because to get a good smooth curve takes a lot of concentration, but it's not that hard. I traced a template from a
picture of the batarang I found on google images, but to make things easier, I've posted a new picture of my template on step two of the instructable.
Good luck!

hottamaleindustries says: Aug 15, 2010. 6:45 PM REPLY

Have you tried throwing it? Just curious.

spookylean says: Aug 15, 2010. 6:54 PM REPLY

I'm afraid of shattering it into a million pieces... maybe when I make one out of steel.

goku ssXXX says: Aug 19, 2010. 7:15 PM REPLY

you could try throwing it at a pillow or a couch :D just to try it out

Verga says: Aug 18, 2010. 8:47 AM REPLY

Very nice job, added to favorties and antoher thing to add to the "to do" list.

kaptaink_cg says: Aug 17, 2010. 5:47 PM REPLY

I really like that. Great idea, and nice looking finished product! 5 stars from me.

spookylean says: Aug 17, 2010. 6:24 PM REPLY

Thank you!

bluesquirrel says: Aug 16, 2010. 5:20 PM REPLY

This is pretty cool! And better yet, it translates into instructions for making almost any retractable throwing-blade type thing (ninja stars, batarangs, etc etc)
for a costume :D

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/
 propninja says: Aug 15, 2010. 10:49 PM REPLY
if you're going to make a metal Batarang I recommend aluminum. you can work it with the same tools you used for the plastic version and it will be far more
durable

Soksume says: Aug 15, 2010. 5:29 PM REPLY

not really a batman person myself but you did end up with a beautiful end product

spookylean says: Aug 15, 2010. 6:54 PM REPLY

Thank you!

http://www.instructables.com/id/Batarang-from-Arkham-Asylum-Game/