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Netflix Daredevil Billy Clubs
Daredevil has been known to wield a multi-purpose weapon that has many different modes. It's initial form is two billy clubs held together by an extendable cable. It can shift from a nunchaku- like weapon to a manrikigusari (a long rope/chain weapon with two weights on its ends), dual billy clubs which can be wielded in an Eskrima-like fashion, staff, or a cable with a grappling hook. The weapon can also be adjusted to combine both sticks into an Eskrima stick. Most notably, the billy club can be disguised as a blind man's cane, for use by DD's alter ego, Matthew Murdock. The weapon is held by a holster on the side of Daredevil Suit's on his left leg
excerpt taken from Marvel Database
The clubs was is all theory fairly easy prop to do. I started like I always do and find as much photo references as possible. Across several boards the lengths seem to agree beign one club is 12"and the other 14". Well thinking about it - both clubs will be 12" with a separate center piece. I decided to utilize some materials I had around my workshop and picked some 1" aluminum pipes. I cut two lengths of 12" actually I cut 14" - always safe than sorry. I laid out the design on paper figuring the various elements. The head would be 2" long, there is a smooth surface section 1/2" wide near the tail and a catch ring (used for the holster) close the head. I figured on 5" from the tail would be the smooth section and 1 1/2" from the head cap would be the catch ring. I took the pipes and mounted them on my 1900's south bend lathe and centered the best I could and began knurling the hand grips (just in case you are unaware of the terminology, knurling is the process of making the cross hatch pattern for grips). I knurled all expose hand grips and buffed it slightly for a nice finish making sure not to knurl the smooth part near the tail, head cap and catch ring. Next I trimmed up the pipe to 12" and set them aside.
I then went to work on the end cap. Before anyone jumps up and says your process is not screen accurate, I am trying to keep the price down for my build and using some stock I had. All the plastic used on the clubs I acquired from a friend who used to work for a medical part company. I have all kinds of scrap. I proceeded to start turning the head cap down. The accurate version the head is the same thickness as the body. Well I tried to turn the piece as thin as possible without melting our damaging. I then bored out the plastic to the thickness of the body. After satisfactory sizing I use the lathe and press fitted the head and body together with a few shots of glue for adhesions. I then turned the decorative rings on the head and then onto the catch ring. I planned my build out and allowed for the ring on the length of the head - so instead of 2" head it was 2 1/4" allowing 1/8" for my cutoff tool. So all I needed was to separate the ring and slide it into place, super glue and I was done. I buffed the plastic with fine steel wool as it rotated on the lathe which took away a lot of the machining markings.
The tail cap was the same way except I turned the outer edge to the thickness of the body and the plug to the inside diameter of the pipe, glued and I was almost done. While I turned the head caps I also turn the center piece so everything was the same thickness.
The center piece I figured on 2" to match the heads with 3/4" plugs. I bored out the center to 5/8" for my embellishments. With both clubs and center section done I drill holes for my locking pins and counter sunk slightly. I uses tent pole clips as my locking pins - excellent move.
My embellishment at the time of construction was the addition of a thin wire cable converting the clubs into nunchucks. The cable length is longer than the traditional nunchucks - 20" long. One end of the cable is connected to a plug with a little slack inside the club to help feed the cable back when not in use. The other end was loop around both tent pole clips inside the center section. I can't take the credit of this initial concept but my attachment of the cable I can. Painted the body the same color as my helmet and sliver metal paint on the caps. Done