8 Foot Tall Skeleton From PVC, Pool Noodles, and Spray Foam

Awhile ago, I made a 8ft tall pumpkin skeleton for the front yard. This year I decided to recycle the pieces and make a Skeleton using PVC, Pool Noodles, and Spray Foam. The bones for this skeleton are a vast improvement over the last version and will be a combination of multiple styles of craft tutorials that have been collected over the years.

The goals of this project are the following: The skeleton will be 8 feet tall. The main structure will be supported by a pole and be as light as possible. The skeleton can be operated similar to a puppet.

The project uses a pole design.

The project uses flex tubing and cable ties to hold PVC for arms and legs together.

The project uses popsicle sticks, hobby foam sheets, and cable ties for hands. Spray foam is used to cover bones of PVC. Hobby foam sheets are used for the hands.

MONEY ALERT: This project was done over a period of time and additional materials increased the cost. Pick and choose what you wish. For example: The gripping hands look cool, but arent really needed. These can be made with spray foam. For example: I used a skeleton mask. Please substitute what you wish for the skull.

Supplies

NOTE: Supplies are repeated in case just one aspect of project is desired to be done.

For the Head: Skeleton Mask, spray foam (Locktite), plastic bags, spray water bottle, PVC (Neck), Heatgun

For the Torso: 8 ft tall by 1/2 inch inner diameter with 5/8 inch outer diameter PVC (NOTE: I recycled 3/4 inch PVC for the images), duct tape, 4 ft long pool noodles (recycled) (4x), cardboard, glue, duct tape, machine screws (3x) and nuts (3x), scissors, utility knife, scissors, cable ties, spray water bottle, handsaw, spray paint

For the Waist/Pelvis: Foam mat, flex tubing, cable ties, heatgun, utility knife, spray paint

For the Legs/Feet: 2 ft long by 1/2 inch inner diameter with 5/8 inch outer diameter PVC (4x), 5/8 inch inner diameter with 7/8 inch outer diameter flex tubing, spray foam (Locktite), black plastic trash bags, old shoes, heatgun, spray water bottle, hobby foam sheets

For the Arms/Hands: 2 ft long by 1/2 inch inner diameter with 5/8 inch outer diameter PVC (4x), 5/8 inch inner diameter with 7/8 inch outer diameter flex tubing, spray foam (Locktite), popsicle sticks, disposable safety gloves, cable ties, twine, straws, heatgun, straps, spray water bottle, utility knife, scissors, glue, hobby foam sheets

BONUS: extra PVC, 90 degree PVC elbow, 8 rings, rubber bands

Step 1: Make the Skull From a Mask

1. Insert and line the bags inside the interior of the skull mask.
2. Spray inside of bags with a light even mist of water.
3. Warning: Use can of spray foam in a well ventilated area. Spray can of spray foam into bags until skull cavity is full.
4. Wait 5 minutes.
5. Inspect foam to make sure it did not inflate unevenly.
6. If it did inflate unevenly, press and shape to fit without touching foam.
7. Wait 5 more minutes.
8. Inspect foam to make sure it did not inflate unevenly or if areas need more foam. Add as needed, and repeat.
9. Allow foam to dry for 24 hours.
10. Remove bag with foam from skull mask without damaging the skull mask.
11. Remove the bag from the newly formed head foam. If bag is stuck to foam, trim off excess bag so that it is not visible when skull mask is installed back onto head foam.
12. Bend PVC to match angle of neck.
13. Insert PVC into foam of head.
14. Install skull mask back onto foam head shape.
15. Install skull mask and PVC neck onto torso when torso is complete using cable ties.

Step 2: Make the Torso From PVC and Pool Noodles

1. Estimate dimensions needed for skeleton by going to humanproportions.com. Input 8 ft for size of skeleton. Record the dimensions for later. NOTE: This PVC will support the majority of the weight of the skeleton costume so bend piping so that torso hangs infront of the human operator.
2. Using a heatgun, bend the PVC piping into this shape for PVC 1. Bend 90 degrees at 1 ft for shoulder (bend1). Measure 2 ft 4 inches from bend1 to base of spine (bend2). NOTE: Sizes will vary based on human operator and distance to skeleton. Bend 45 degrees for bend2 toward human operator. Bend 45 degrees for bend3 so PVC is offset parallel to spine that would align with human operator. Bend 90 degrees across human operator belly (bend4). Trim PVC to fit after it crosses PVC 2.
3. Using a heatgun, bend the PVC piping into this shape for PVC 2. Bend 90 degrees at 1 ft for shoulder (bend5). NOTE: Sizes will vary based on human operator and distance to skeleton. Measure from bend5 to bend6 that matches distance to human operator. Bend (bend7) straight down to support weight of skeleton and parallel to human operator.
4. Drill holes at shoulder for PVC1 and PVC2. Insert machine screws and nuts to hold together.
5. Drill holes at the spine for PVC1 and PVC2. Insert machine screws and nuts to hold together.
6. Drill holes or use cable ties for PVC 1 and PVC2 that cross at the waist and support pole PVC2.
7. Trim off excess PVC EXCEPT THE SUPPORT POLE PVC2.
8. Cut pool noodle #1 to match shoulder length.
9. Cut a slit along the length of pool noodle #1.
10. Cut pool noodle #2 to match spine (from shoulder to navel per website).
11. Cut a slit along the length of pool noodle #2.
12. Fit shoulder pool noodle #1 over T-shape of Torso.
13. Fit spine pool noodle #2 over vertical spine of Torso. NOTE: Make sure slit is toward the back of the Skeleton.
14. Tape or glue pool noodles together at T-intersection.
15. Cut one pool noodle #3 as same length as breast plate (2x length of shoulder to nipple per website).
16. Cut slit along length of pool noodle #3.
17. Flatten pool noodle #3 and glue onto a piece of cardboard.
18. Cut cardboard and pool noodle #3 into shape of breastplate.
19. Cut a new pool noodle #4 to match shoulder length.
20. Cut slit along length of pool noodle #4.
21. Slice pool noodle #4 into 4 equal parts along length of pool noodle. These will be the ribs. NOTE: Remove edges of ribs to make more round.
22. Cut a new pool noodle #5 to match shoulder length.
23. Cut slit along length of pool noodle #5.
24. Slice pool noodle #5 into 4 equal parts along length of pool noodle. These will be the ribs. NOTE: Remove edges of ribs to make more round. NOTE: If more ribs are needed, repeat steps.
25. Tape or glue pool noodle ribs onto breast plate pool noodle #3. Try to space ribs evenly and symmetrical based on human ribs. NOTE: At this point in time, breast plate pool noodle #3 looks like an eight legged spider.
26. Cut a new pool noodle #6 to match depth of desired chest cavity.
27. Tape or glue end of pool noodle #6 to front of spine where cavity of chest will be.
28. Tape or glue other end of pool noodle #6 to center of rear or cardboard of breastplate pool noodle #3. NOTE: This will support the eight legged spider shape.
29. Tape or glue other end of ribs to spine. Try to space ribs evenly and symmetrical based on human ribs.
30. Cut a new pool noodle #7 to match depth of chest cavity.
31. Cut slit along length of pool noddle #7.
32. Slice pool noodle #7 into 4 equal parts along length of pool noodle. Two of these will be the collar bones. Cut collar bones to fit. NOTE: Remove edges of collar bones to make more round.
33. Tape or glue collar bones onto shoulder and breast plate. Try to space evenly and symmetrical based on human collar bone.

Step 3: Create Pelvis From Foam Mat and Flex Tubing

1. Drill hole through PVC 2 at bend when spine is located.
2. Cut flex tubing to reach from base of spine to pubic area. NOTE: This will support the weight of Left leg.
3. Repeat for second flex tubing. NOTE: This will support the weight of Right leg.
4. Use heatgun to bend tubing into shape of image. Secure into shape using cable ties.
5. NOTE: In order to cut the foam into shape, imagine the pelvis area shape as a folded paper cup or cupcake paper liner. For this instructible, we will bend the foam into shape for the spine/tailbone, then shape the wings of the iliums (waist bones), and then finally the pubic area. All of this will be done while incorporating the flex tubing into the structure.
6. Trace where on the foam that the width of the spine will be and circle. NOTE: Do not cut at this time. NOTE: Circle diameter should be roughly same as the inner diameter of flex tubing shape so that flex tubing wraps around foam.
7. Bend one corner of the foam up for the spine/tailbone.
8. Cut a V and circle shape in the center of the foam for the end of the tailbone and center of the pelvis.
9. Trim off the foam for the spine and top of the wings of iliums (waist bones).
10. Using heatgun, bend spine into shape. Hold in place with cable ties. NOTE: Make sure the smooth side of foam is facing up. I had to rebend foam when I bent on wrong side.
11. Bend the two adjacent corners up for the wings of the iliums (waist bones).
12. Insert tubing along outer cup of pelvis. Shape using a heatgun.
13. Use cable ties along foam where tubing will be in spine.
14. Trace the shape of the wings and then trace pubic area around flex tubing leaving room for the femur leg sockets. NOTE: Contrary to actual shape of pelvis, try to keep pubic area as one solid piece to maintain strength. Also ensure there is a minimum of 2 inches of material around tubing for strength.
15. Use cable ties at pubic area. If shape does not keep, use cable ties to flex the foam into shape.
16. Use heatgun to shape to match human pelvis.
17. Insert cable tie into hole at the spine. Secure flex hose and pelvis to spine using cable ties.

Step 4: Create Legs From PVC, Flex Tubing, and Spray Foam

1. Insert Lower Leg PVC 3 into flex tubing.
2. Measure depth of insertion.
3. Measure 6 inches above insertion and cut flex tubing for knee.
4. Measure length of flex tubing for knee and cut same length for other knee.
5. Lay trash bags onto a flat work surface.
6. Liberally spray water onto trash bag.
7. Lay flex tubing and Lower Leg PVC 3 onto trashbag.
8. Use can of spray foam onto Lower Leg PVC 3 to make lower leg shape.
9. Spray a second plastic bag with water. Lay plastic bag on foam in shape of bones. NOTE: The legs in the images are too lumpy so this step was added to smooth out the bones.
10. Wait 5 minutes. Allow foam to swell and smooth out into shape based on its expansion just like yeast and bread dough rising.
11. Remove plastic bag. If surface is sticky, lightly, spray surface of spray foam with water.
12. Wait until surface is not sticky which might be 3 more minutes. NOTE: Do not wait too long.
13. Stretch and shape foam into shape of bone.
14. If necessary, flip bone facing down and repeat steps for back of bone.
15. Repeat step 7 to step 13 for Lower Leg PVC 4.
16. Bend Femur PVC 5 to represent ball socket. A. Measure 3 inches from end and bend 45 degrees using the heatgun. B. Measure 1-2 inches and bend another 45 degrees using the heatgun.
17. Insert knee of Femur PVC 5 into flex tubing of Lower Leg PVC.
18. Use can of spray foam on Femur PVC 5 to make Femur shape. NOTE: Do not cover end where flex tubing will be on pelvis. Repeat steps 7 to step 13 for Femur PVC 5.
19. Bend Femur PVC 6 to represent ball socket.
20. Insert Femur PVC 6 into Lower Leg PVC.
21. Use can of spray foam onto Femur PVC 6 to make Femur shape. NOTE: Do not cover end where flex tubing will be on pelvis. Repeat steps 7 to step 13 for Femur PVC 6.

Step 5: Create Hands and Lower Arms

NOTE: Some of the images were from a first attempt. Images with extra popsicle sticks are not needed. The instructions were simplified to current list.

1. Group two thick popsicle sticks together.
2. Wrap 4 cable ties around popsicle sticks. Separate cable ties to form bones of hands and wrist bone. Ensure cable ties are arranged to lay the same.
3. Glue 4 popsicle sticks along the cable ties.
4. Glue large popsicle stick across the four popsicle sticks to form the knuckle of the hand.
5. Mark on cable ties expected location for each joint of fingers from the knuckle.
6. Glue straws on inside palm along each cable tie. Make sure straws reach the last joint of each finger. NOTE: Lay straws face down to apply pressure for glue to hold in place until it dries.
7. Cut 1/4 inch V-shaped opening at straw for each joint of fingers to include the knuckles.
8. Group four thick popsicle sticks together.
9. Attach cable tie to location where joint near thumbnail will be.
10. Drill a hole through other end of popsicle sticks using a utility knife or drill bit. NOTE: Drill hole by hand or the wood will split.
11. Spread popsicle sticks and fit around index finger bone near wrist bone.
12. Use cable ties to squeeze popsicle sticks together around index finger bone.
13. Glue thumb into place to keep from moving.
14. Trim excess popsicle stick wood to get general shape of a hand.
15. Cut a slot into end of PVC 7 for lower arm. Ensure slot is same width and depth as popsicle stick used for wrist.
16. Drill a hole from end of PVC 7 about 1 inch away from wrist. Ensure hole is perpendicular to slot.
17. Use cable tie to secure wrist to lower arm PVC 7.
18. Drill a hole into lower arm PVC 7 about 3 inches from slot. Ensure hole is inline with slot.
19. Drill a hole into lower arm PVC 7 about 6 inches from other end near elbow. Ensure hole is inline with other hole.
20. Cut twine into 4 strips that are the same length as end of PVC 7 elbow to finger tips.
21. Cut a 5th string to use as a feeder. Insert 5th string into wrist hole and feed string all the way to the elbow. Leave plenty of string on each end to use for feeding.
22. Insert 2 strings into wrist hole on one side to reach other hole across the piping.
23. Tie all four strings to the 5th string.
24. Pull four strings to elbow.
25. Once four strings reach end, pull four strings through elbow hole.
26. Tie four strings together to keep from accidentally pulling strings back through hole.
27. At wrist, insert each string into straws of fingers.
28. Once strings reach fingertips, tie strings onto tip of finger past joint.
29. Glue strings to fingertips.
30. BONUS: A. Use single knot tied from all strings tied together to act as a single close hand. OR, B. Tie each string to a ring and a rubber band. These are in turn tied to a PVC section attached to a 90 PVC elbow. The PVC elbow serves as a palm grip for the operator's hand.
31. Use can of spray foam to create bones. NOTE: Do not cover string.
32. Spray plastic bag with water. Lay plastic bag on top to shape bones.
33. Wait 5 minutes. Check surface for stickiness. If sticky, wait another 3 minutes until not sticky.
34. As soon as skin is not sticky, shape bones. NOTE: Dont forget the second forearm bone and wrist bones.
35. Cut hobby foam sheets into 2-3 inch wide strips that cover the length of the finger bones. Make sure width can wrap around each finger.
36. Cut strips to match each joint of finger bones while leaving tabs that can wrap around each finger bone. Refer to images.
37. Cut into shape and glue strips onto finger bones. NOTE: Make sure strips are glued to outside of the finger joints and do not interfere with bending of joints.
38. Wrap tabs around finger bones and glue into tube shape.
39. Cut strips for the palm of hand and glue to cover gaps. Decorate as needed.
40. Repeat step 1 through step 39 for PVC 8. NOTE: Make sure fingers and thumbs are at correct locations. Don't make two hands that are the same, but are mirror constructions of each other.

Step 6: Create Upper Arms

1. Use can of spray foam to create bones. NOTE: Do not cover ends where flex tubing will be.
2. Spray plastic bag with water. Lay plastic bag on top to shape bones.
3. Wait 5 minutes. Check surface for stickiness. If sticky, wait another 3 minutes until not sticky.
4. As soon as skin is not sticky, shape bones.
5. Test fit bones to flex tubing.

Step 7: Create Feet

1. Use old shoes as basis for shape of feet.
2. Wrap shoes in plastic bags.
3. Place plastic trash bag onto flat work surface.
4. Spray water onto plastic trash bag.
5. Arrange cable ties into shape of toe bones of feet.
6. Use can of spray foam to make toe bones of feet.
7. Use a second plastic bag and spray with water. Lay on top of the bones and roll into shape.
8. Wait 5 minutes. Test for stickiness. If still sticky, wait 2 minutes.
9. As soon as surface is not sticky, use string to indent bones into shape of joints.
10. Once shape of bones is achieved and while foam is still limp and not hard, lay bones on plastic covered shoes to allow it to dry into a foot shape.
11. Once completely dried and hard, perform next step.
12. Lightly spray bag covered shoes with water.
13. Use can of spray foam to create small drops of foam to create heel and ankle bones on shoe.

Step 8: Paint and Assemble

1. Spray paint the skeleton.
2. Assemble. NOTE: If I had to do it over, I would cover the taped pieces with spray foam and measured the joints better so that the bones overlap.
3. Setup for display.