The Darkslicer: a Batarang Design From the Dark Knight Movies

This is a Batarang design based off of the ones shown in the Dark Knight movies. The Sketch used to make this design was made by SolarCool from Onshape. Thanks! 1/8" thick Steel is recommended to use for this project. You shouldn't go thicker, but you could go thinner, especially if you're going to use this for decor only. Thank you for reading this Instructable!

Tools:

• Dremel with Flex shaft attachment
• Dremel metal cutting wheels (x5+)
• Dremel orange grinding cones
• Sharpie
• Xacto Knife
• Printed Paper Template
• Angle Grinder with Flap disk (or a Worx Chopper with my 3D Printed Sanding Disks https://www.instructables.com/Worx-Chopper-Sanding-Wheels/)
• Paint (optional)
• Personal Protective Equipment (PPE) (Earplugs, Safety Glasses)

Materials:

• 1/8" or thinner sheet of steel at least 12" long and 6" wide
• Cardboard at least 12" long and 6" wide

Using your angle grinder with a Flap Disk, grind/polish an area on both sides of your steel that is at least 12" long and 6" wide. The Worx Chopper with my sanding disk accessory worked great!

Next is using the Xacto knife to cut out the paper following the design's outline. You'll probably want to cut on a flat, protected surface, like a cutting mat. Be slow and precise to produce the best results. The included PDF file is the paper template for you to print. Then, use the paper design you cut out as a stencil to trace the design onto your piece of cardboard with the Sharpie. Having done that, use the Xacto knife(or scissors if you're good with them) to cut out the design that you traced onto the cardboard. One way to do this is to make a scoring cut along the lines first, then follow that score and pierce all the way through. Then, using the design that you cut out of the cardboard, trace the design using the Sharpie onto the metal.

Now hook up your Flex Shaft attachment with a metal cutting wheel to your Dremel, then cut out the design you traced onto the metal. Make sure that you wear all necessary PPE. For best results, make a shallow score along the lines, then cut all the way through like you did with the cardboard. It's safer to air on cutting on the outside lines. You will be grinding it down later. Prepare to use many cutting disks! The Dremel worked great, but in retrospect it probably would have been better to use an angle grinder to cut the long straight lines and use the Dremel for the more detailed cuts. When you've finished cutting, you may need to use a hammer to tap out the design.

Then I used my Worx Chopper to polish it a little more. If you don't have a chopper, an angle grinder with a flap disk will work. After doing that you can sharpen the edges. I only sharpened the long straight edges and the tail. If you only sharpen some edges also, it would be a good idea to take the Dremel with a grinding stone and dull the unsharpened edges so they don't cut your hand when you hold the Darkslicer.

It works great! If you want you could paint it, and for added effect you may want to grind the paint of off the sharpened edges. When thrown at the end of a log, it penetrates 1/2" deep! The performance will be affected by the thickness of your steel: The thicker your steel, the deeper it penetrates. To thick steel, though, and it'll not be skinny enough to pierce anything. Thank you for reading this Instructable. Please let me know if you have any questions, comments, or concerns. Thanks!