Re: The Dark Knight New Costume PHOTO Thread.
I had this happen to me on my original suit Bats. For me it wasn't removing the hand that caused it to break but rather trying to bend the wrist too far, or in the wrong direction (eg side to side when the ball was positioned for back and forward motion). Lightly sanding down the pegs will help the hands to swap in and out easier, and also makes the joint a bit more likely to turn to the right direction if you try bending it the wrong way. If it does break, apparently it can be fixed by heating up a sewing needle and inserting it into the plastic between the broken peg and ball section, then using a bit of super glue to complete the joint. It might be worthwhile trying to reinforce the joints before they break by doing that (it kinda makes sense - the plastic holding the peg to the ball is quite thin, so inserting a metal pin into it should make it stronger) but don't blame me if you try it and it causes problems!