Animated Jack-O-Lantern

Step 2 Form the Frame

The first step is to build the frame that everything will be attached to.

To do this you will first need the measurements of your pumpkin; the maximum internal height and depth from front to back (you can just eyeball it). This will allow you to form it into the shape in the last picture of this step.

The first step is to create the overhang where the Flexinol will attach.
To do this, measure about 5 cm from one end of the aluminum channel bar and mark it on the side without the opening.

Next, draw 2 lines at 45 degrees from the back of the bar

Now cut along the lines using the tin snips (you could use a hack saw, but it would be very hard) and then cut the back side to match (See pictures).

Now simply bend it with your hands to a 90 degree angle.

Repeat these steps for each corner, being sure to measure along the back of the bar. This is so the extra material ends on the inside and it still fits in the pumpkin.

When you have made the last bend, cut off the extra material about 1 cm above where you want the middle of the moving pumpkin parts to be.