Below are excerpts from the DC Prop Builders Handbook.
The pictures and complete instructions have been removed.


Skeletal Organist

What you will need:

1 full Bucky skeleton
Piano bench
3 4’ 1” metal bars
1 2’ 3/4” metal bar
2 4” 1.25” “L” bar
1 35 RPM Mc Master Carr motor part # 6142K56
1 20 RPM Mc Master Carr motor part # 6142K55
2 3/16” wire rope clips
1 piece of 3/4” polyethylene
4 3/8” X 1 1/8” 1” & 1.5” long 1/4” bolts and nuts w/ lock and plain washers
Nylon lock nuts1 1.5” washer2 3/8” washers
2 6/32” machine screws (2.5” long) with nylon lock nuts
4 3/4” .478 springs (non compressed)
2 1” compressed springs
1 1/4” round rod 36” long
1 2.5” hinge with removable pin

The first thing you will need to do after you have finished collecting all of the needed parts will be to build the chest cage and vertical mounts. To do so first cut the following out of your 1” straight bar: 4 @ 8”, 4 @ 5”, 2 @ 2.75”, 2 @ 4.5”, 1 @ 11”, 1 @ 4.5”, and 2 @ 7.75”. Now cut the following from your 3/4” bar: 2 @ 7.5”, 1 @ 2.5”, and 1 @ 3”. Finally cut your 1.25” “L” bar to the following sizes: 2 @ 18”, 1 @ 6”, 1 @ 4.75”, and 2 @ 1.25”. After you have cut all of the necessary pieces, de-bur and smooth out all of the edges.

Once you are done cleaning up the metal, you are ready to build the chest cage and vertical mounts. To build the chest cage you will need to take the two 5” straight bars and bend each end 1” from the end at a 90-degree angle. These will be your vertical mounts. Now take the two 4.5” bars and two of the 8” bars and bolt them together (8” bars on top). For the second 8” bar you will want to put a bolt and washer separating the bars, so you have a bit more lean on the organists neck (see fig). You should now be left with a rectangle that is 8” x 4.5”. After your rectangle is build take the bolts out of one of the 8” bars, but clamp the bars together making sure they remain square.

Once that is done, you will need to connect the vertical mounts that you bent to this rectangle. Use the previous holes from the rectangle as pilots, drill and bolt the mounts to the rectangle (see figure).

Now take the last two 8” bars and the 2.75” bars and build another rectangle. The 8” bars should lie on top of the 2.75” bars. Now take the 8” x 2.75” rectangle and mount it to the bottom of the vertical mounts you bent. You should be left with somewhat of a rectangle that looks like the picture below.

We will now make the vertical spine mounts. To do so, you will need the two 18”, the 4.75”, and the two 1.25” “L” bars. Take the 4.75” bar and connect it to the base of the two 18” bars. You should end up with an open-ended rectangle with a 4.75” width, make sure to keep the base and vertical mounts are perfectly square. Once that is complete, take the two 1” “L” bars and drill a 1/4” hole in the center of each end. Now bolt one to each top of the vertical spinal mounts, with the ends pointing outward (see figure), this is where you will mount your chest cage to the spine mounts. The holes for the 3” vertical mounts and the holes for the 18” vertical mounts should be inline with each other. You can now paint the two parts with black anti-rust paint and let them dry. Once that is done and sturdy, we are ready to start taking the skeleton apart.

Before we take the skeleton apart, we need to straighten out the spine. To do so simply lay the skeleton on its back and step on the spine in the stomach and neck regions. Now to take the skeleton apart, first remove the arms, legs, skull, and loosen the spinal rods. Now remove the small spinal rod and discard it. Now cut the main rod at the 7th vertebrae, just above the first rib. Now cut below the 10th and another cut below the 13th vertebrae. Remove the section from the 1st-7th vertebrae and then remove the rib screws from the 11th-13th vertebrae and remove that section. Now remove the 7th, 11th, 13th, and 14th vertebrae and tap the exposed rod so you are able to fasten a bolt to each end. Once that is done remove a portion of each of the vertebrae you removed, to allow a bolt to lay flush with the top. Now reapply the 13th vertebrae and tighten the bolts to re-strengthen the lower skeleton. Now take the 7th vertebrae and cut it down the center so it is now 1/2 an inch high instead of 1 inch. Now take one of the 5” pieces of straight bar and make 2 bends that are opposite of each other, one at 1.5” and the other on the opposite side at 1”. Now drill a 3/8” hole on each bend, then with the 1.5” side, insert the exposed rod from the 7th vertebrae and tighten the bolt so that the bar’s 3” vertical surface is at the front of the neck pointing downwards. Now tighten the bolt that is on the inside of the skull so the neck, the skull and the mounting bar are solid. That is all of the modifications we will need to do for now, so set the skeleton aside.


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