Articulated Wing Framework

A skeleton set of wings made from balsa wood and an old frame backpack, suitable for angels, bats, demons, birds (but not so much for butterflies or other insects). They open and close as you raise your arms, and flap forward and back when you do. Decorate them with leather, feathers, streamers, gold paint, whatever strikes your fancy. Mine ended up with a 9 foot span when open fully.

I wanted a very lightweight wing that would not tire me if I wore it all night. I chose balsa wood over aluminum tubing because it's easier to work with given the tools I have available. The basic structure could be made out of almost any stiff material, however. (My prototypes were made from popsicle sticks and foam core.) Each wing is a simple set of linkages arranged to expand and rise when opened.

Step 1: Tools & Materials

Except for the backpack, which you may be able to find in a thrift store or Army Surplus if you don't already have one in your garage, all the materials needed can be found in a hardware store and/or craft store.

(A) 1 aluminum frame backpack
(B) 3 pc of 36" x 4" x 1/4" balsa wood
(C) 1 pc (60" length) of 1/4" wood dowel
(D) about a foot of "hanger strap" - a thin strip of metal with holes in it, mine came coiled up in a packet (found in the plumbing section)
(E) 4 nut/bolt sets, bolts of a diameter to fit through the holes in the hanger strap, and as short as you can find (they are used to fasten the hanger strap tight around the wing supports)
(F) 8 shaft collars with inside diameter 1/4"
(G) 6 pc 3/4" machine screws that fit the threadings in the dowel collars (F)
(H) 2 pc 1/2" machine screws that fit the threadings in the dowel collars (F)
(J) 4 pc 1/2" binding posts for the balsa/balsa hinges
(K) 2 pc 3/8" binding posts for the balsa/hanger strap hinges
(L) 10 pc 1/4" long nylon spacers, that the binding post (J) fit through
(M) 6 pc 1/4" long nylon spacers that the machine screws (G) will fit through (and turn; these will be some of the wing hinges)
(N) 4 nylon washers, 1/16" thick, that fit around the binding posts (J)
(P) a number of small nylon washers, 1/16" and 1/32" thick, that fit around the machine screws (G) ¹
(R) 2 nylon flanges (I am not entirely sure this is the right term) to fit into the aluminum tubing of the backpack
(S) scrap leather
(T) couple inches of velcro

¹ these washers are to pad the hinges created by the collars & the machine screws, so the thicknesses are determined by the actual dimensions of the hinge assemblies. I used, I think, 8 of the thicker ones and 6 of the thinner ones, but I suggest buying these later once you're ready to assemble the hinges and can take the wing parts into the hardware store and measure, or just get a bunch and use them as needed (they cost me something like 6 cents each).

Tools:

• x-acto knife
• Dremel or power drill with a cutting wheel attachment & a 1/4" metal drill bit
• tin snips (you can use the cutting wheel if you don't have tin snips)
• 2 pair needle nose pliers
• wood glue
• hot glue gun
• screw drivers appropriate for your bolts and screws
• sandpaper or fine file (I use fingernail files)
• sewing machine or needle & thread

Comments

[Kirike]

did you cover yours with feathers? for the project i have in mind id have to cover it in feathers, and i am not sure how to go about doing that!

[lharlett]

http://flamiekitten.tumblr.com/post/46260200282/cries-tears-of-joy-etc-look-whats-finally

Thank you much for your tutorial, my Dad and I had a good time making these together! :D

[Unihorn]

Thanks again. Suggestions: avoid drilling large holes in the wood for the inserts and use large washers instead. I had chunks break out trying to drill the hardwood trim. Longer bolts to account for the washers. Metal rods instead of wood where it attaches to the backpack. Heavier gauge steel strapping. Cut the wood with a jigsaw and then a dremel to round all edges so things don't catch.

[Unihorn]

Amazing engineering and the best instructions I've ever seen on here. I'm a Halloween costume nut and this will be the first time I'll avoid a month of trial and error and 10 part runs to the hardware store. Do you have a PayPal account that I can use to send you a few bucks for the plans?

[rachel]

Thank you so much for the compliments! No need to send me anything, just make an awesome set of wings and post pictures when you're done. I do advise not using balsa wood as it turned out not to be strong enough for multiple wearings, I got I think two parties out of these wings before the hinges started to pop out :( whiteoakart's idea of 1/8" birch plywood is probably what I'd try if I made these again.

[Unihorn]

I think I might splurge and go with bar aluminum. I priced aluminum at $22 for 6' or an L shape aluminum at $10/6'. I've learned over the years you have to factor in the labor cost of rebuilding items and that I am good at running into things with a giant mascot head on :) Thanks again.

[whiteoakart]

I am using 1/8" birch plywood from the hobby shop. It is much stronger than balsa, but still inexpensive, very light, and easy to work with.

[Cresco]

Just thought I would share! I used your instructable to make a Halloween costume for my son this year. Thank you very much for the inspiration!

http://www.coolest-homemade-costumes.com/coolest-homemade-toothless-the-dragon-halloween-costume-idea-4.html

[whiteoakart]

That's a really nice costume you made for your son, Jeff. Kudos.

[rachel]

Wow that looks awesome! Thanks for posting it. (Cute kid too :)

[jade12135]

How big width-wise are these? And could I lengthen the leather strap to make them extend more? And would this hold chicken wire and feathers? Sorry about bombarding you with questions ;u;

[ogihci]

Did you cover your wings with feathers? Could you maybe show me? I don't want to cover it all to find out it won't close D:

[dreiling]

great design and instructions on this. i'm currently making a set of these for a motion capture project, and just wanted to thank you for putting this up. it has been a great help though my project.

[DessMia]

I've made a pair of these, but they're kind of awkward to wear. When they're closed, they fall inward and get tangled with my packstraps, and they don't close well when I extend them. Do you have any suggestions on how I might be able to fix these technical difficulties?

[AudioMaximus]

This is a perfect side project for me on my robotics team! I think I'm going to use an aluminum frame instead of balsa would, for durability. Maybe even use some small servo motors or something for opening/closing activated by a switch

[DessMia]

Do you know/remember what brand of backpack you used to make these, I'm looking at some online and the picture shows them with a external frame, but they don't say anything about an internal frame. Should I assume that the packs have one, or not?

[rachel]

I got mine from someone's garage where it had been sitting for I think years. I don't know what brand it was unfortunately, nor do I know if all external frame backpacks have an internal frame too. Try contacting the seller perhaps? If you don't have an internal frame to re-use, you could get some aluminum or even plastic tubing separately.

[dlee32]

I loveee this!! And I'm SOO thankful u posted a tutorial!! XD I just have a question... Do u think the frame would be able withstand additional weight? Say if I draped cloth and wutnot in order to create demon wings?

[kfassett1]

Ive been trying to make a realistic bird costume:) I was going for a maximum ride look. These wings are so perfect! But im not sure i can make them...im not good with these things. would you sell me a pair?

[noob_for_life]

We got a backpack from Craigslist which does have an inner frame. Do you think the thin struts can work for the bent tubes? If not, can you give me some idea of how long the tube should be and we'll try to scrounge something?

Thanks much. This is SUCH A COOL project1

[rachel]

The thin tubes from the inner frame is exactly what I used for the bent tubes that form the shoulder joints.

Thanks for the compliment! Post a pic when you're done!

[Darkone99]

where does the 2 bent tubes come from??

[rachel]

Sorry I missed this question at the time! My backpack had an inner aluminum frame inside the pack part, the bit you actually put stuff into. I didn't manage to take a picture of this bit at the time, I'm afraid, so it doesn't show up in this photo set.

[derrondune]

My question is the same as Darkone99. Where do the 2 bent tubes come from?

[rachel]

My backpack had an inner aluminum frame inside the pack part, the bit you actually put stuff into. I didn't manage to take a picture of this bit at the time, I'm afraid, so it doesn't show up in this photo set.

[CosplayProps]

how many inches across is the widest part of your bone Y Ms. Rachel?

[rachel]

Probably about 2", but it's not a vital measurement. You can set the width to whatever works for your material and design needs.

[TheBoneCarver]

Rachel: Thank You! With the help of your Instructable, I was able to construct one of the "hit" costumes at Wild Wild West Con 2011 for my wife.

To help Cat Spang out: I didn't use a camping backpack. I purchased a 10' section of PVC pipe, some elbows and end caps to construct the framework. It reduced their width and made them much more comfortable for my wife to wear. Here's a picture of the back and the full outfit with the wings open.

I'm working on a stronger version that uses aluminum for the bones, conduit for the frame and piano hinge for the hinge.

[rachel]

These are amazing looking! I hope you post pictures of the new version, or even an instructable about it, it looks like you've made a ton of improvements on how the wings are attached.

[ewickerham]

This is a wonderful idea and i am addicted to the idea of having wings, one year for halloween i had made those lil fairy wings out of wire hanger and stockings but i rlly want feathered wings. so i look at all these websites and find how to make wings out of cardboard..... well those wings are great but they dont move >.> so after a while of searching for articulated wings i found this, i love this idea and think it would be amaizing but i was wondering, how do u make the skin or feathered part???... and do i have to buy a really good quality backpack? cuz it cant get too pricey.... i LOVE this idea.. im trying to think how to cover the ugly frame... i mean it is beatiful work its just not what u want to see when u are supposed to be looking at a pair of angel or elsewise wings..... BUT I LOVE THIS!!!

[rachel]

A little while ago I saw where someone had made similar wings like this, but instead of using a backpack, they had made slots in a corset, to slide the wing supports into. If I were to make these again, I would use that method, it is much sleeker and made the wings really look like they were attached. Unfortunately I didn't save the link to it :(

[Moldragath]

ya i was wondering where i could get a template for the wood cut outs, thanks!

[Moldragath]

sweet thanks, great job, by the way, has any one that has made these added fethers and if so how lol?

[ewickerham]

There are many ways that i have thought of and seen videos of and actual documentaries of, the most common ones are to line the proper parts of the frame with chicken wire to the appropriate shape u desire. Then cover that with the same color fabric u would use for the wings. u have to get the right parts of the frame lined though, otherwise it wont bend..... there is a video on youtube on how to make moving angel wings out of a towel drying rack. i think it is a wonderful easier and much more understandable (to a 13 yr old female's mind). i was thinking that her wings are cute but since she was new to making wings, she could have modified the shape of the chicken wire to give it a much less boxy shape and well (u have to watch the video to understand this) i cant think of any other Mats other than duct tape, to attach them. her "harness" is a lil kinda gaudy but if decorated properly, it could be just fine.... btw her harness was much smaller (for those looking for a smaller harness) but it was just the handle of a bike screwed into the drying rack.... i really appreciate this info though

[rachel]

I just drew some shapes in the appropriate lengths that looked good to me. You don't really need a template, just draw on paper making sure that the holes are the right distances apart.

[DessMia]

How long is each bone, from tip to tip?

[Cat Spang]

Wow, these are incredible.
I was wondering, though, do you think there is a suitable alternative for the backpack framework? I can't find any in shops here, and any I can find on the internet are ridiculously expensive,
Brilliant idea though.

Also apologies if you've already answered this question.

[abadfart]

pvc and nylon webbing

[crak-a-bottle]

I've not had a go at this project but perhaps one of those metal chairs that folds flat? The back of it might work. Use belts or something for straps....
Cheap metal ladder might work.

[atuttle]

for the frame work i would say go to your local camping supply shop and get some hiking packs