The epic costume requires much preparation.
Inspired by the designs from supernatural themed movies these stilts are metal and plastic which makes for a safer and longer wearable appendage.
All of the computer generated templates and drawing files are located in the digi.rar file on the materials page.
I recommend that you download and read this entire instructable before beginning your project.
Build early so you can practice and get used to walking in these stilts. Play safe...
You can download the complete instructions in 2 parts in the materials section of this instructable.
I spent approximately $120 to build these. Expect the cost to be between $100 and $200 depending on your local materials availability.
The stilts shown weigh about 8 pounds each.
The stilts pictured were tested thoroughly bay a person weighing 200 pounds plus carrying an additional 30 pounds of weight.
NOTE!!!! To make up for the lack of video I am offering a 1 year PRO membership to the first person that posts a video of stilts based on my design.!!!
Step 1: Tools and Materials
Basic tools needed:
Measuring ruler that can go up to 24 inches
Fabric tape measure
Hand Hack Saw
Drill bits: 1/4, 19/64, 5/16
Heat Gun (not a hair dryer)
1 Lb hammer
Flat Bastard file
Additional tools (optional):
Jig Saw or Rotary Saw
Sewing Machine (If you are making your own straps)
6mm Sintra (6 square feet)
3/8 X 1.25 inch Aluminum Bar Stock (12 feet)
1/4 X 2 inch Aluminum Bar Stock (24 inches)
1 X 2 inch aluminum Bar Stock(6.5 inches)
1 X 2 Rectangular Steel Tube 1/16 inch wall thickness (4 feet)
1/4 20 by 1 inch Grade 8 bolts (36)
1/4 20 by 0.5 inch Grade 8 bolts (8)
1/4 20 Tee-Nuts (40)
1/4 Steel Fender washers(36)
1/4 Standard Washers(36)
1/4 Standard Nut(8)
1/4 Nylon Fender Washers(12)
1/4 by 1/4 Bolt bushing spacers(32)
5/16 X 1.25 inch bolts(4)
5/16 X 2.0 inch bolts(2)
5/16 by 3.0 inch Grade 8 bolts(4)
5/16 by 5.5 inch Grade 8 bolts(4)
5/16 Steel Fender Washers(2)
5/16 Standard Washers(16)
5/16 Nylon Fender Washers(4)
3/16 aircraft cable (6 feet)
3/16 cable sleeves(4)
5/16 by 9 inch turnbuckle(2) Verify the load limit to be over your weight
1.5 inch Velcro Strapping (12 straps 18 inches long)
1.5 inch nylon webbing (7 feet)
1.5 inch Velcro (6 feet)
1.5 inch Tri-Ring (24)
Red Loctite 271 Thread locker
If you are making your own straps then you will not need the pre-made Velcro strapping listed above. The pre-made straps are available at Home Depot but are weaker and considerably more expensive than making your own. I will cover how to make your own in a later section.
If you are unable to find the 1/4 by 1/4 Bolt bushing spacers then you will have to make your own from 5/16 inch steel or copper tubing. You will need a tubing cutter or hack saw for this. I will show the steps to make your own.
Sintra is available at plastics supply stores like Industrial Plastics & Paints. (ippnet.com) There are other plastics available like nylon and PVC but they are a great deal more difficult to work with. Sintra is foamed PVC which is light weight and has the strength required for this project. It is easy to cut and form.
The metals are available on-line from metalsupermarkets.com. If you go to the store be sure to check for pre-cut and scrap pieces which will be less expensive than the full lengths of bar stock.
Bolts and fasteners are available in specialty stores like calfast.com
Nylon webbing, Velcro and Tri-Ring are available from paccana.com or hudson4supplies.com
Big Box stores like Home Depot may have the materials listed here but the prices will be quite a bit higher than the specialty stores.