AFO Brace Info

[RoadWarrior101]

Hey Mates,
With the new year, my plan is to start a whole new Road Warrior costume, and make it as awesome and accurate as I possibly can. I've made a Road Warrior costume starting last April, it was good for a few months, until I just got more and more obsessed with the idea of having an amazing costume, like Max Replica's (although mine will never be that amazing! ) Anyway, So far I have only started with the gloves. It will be a long project, but an enjoyable one at that!
So I figure'd I start collecting some information as early as possible. Seeming how rare and expensive an AFO brace is, I seen some pictures on HUMVEE Drivers site of someone (Patrick?) who made is own AFO brace, and I must say, it looks great! So I figured if someone here could share some info on how I would go about making one like his and also share some measurements on the brace. I shared a poor diagram of what measurements I am looking for below.



Thank you guys! Highly appreciated!

[tk4013]

Give me a few days and I'll post a template, I own a real one

[RoadWarrior101]

Sounds great, mate! Thank you so much, its highly appreciated!

[tk4013]

The total length of the piece is approx. 12" that does NOT include the stirrup. I traced this drawing from the actual brace and I think if you print it, it should come out pretty darn close to the correct measurments listed. The one I have is aluminum(and the stirrup is stainless steel) however stainless steel for the whole thing would be alot more durable Imo (but also heavier). The best way to go would be bring a drawing to a machine shop and have them either plasma, lazer, or water jet cut you out one from some 3/8" stock.

[RoadWarrior101]

WOW!
Thank you so much for taking the time out of your day to do this for a complete stranger. It is really appreciated! There sure are some awesome people on this forum. Who knows, in the future I may be able to return the favor.
Thanks again! I am unsure when construction will begin on my costume, but I will surely keep everyone updated. It's really hard for me struggling through high school, jobless and maintaining a social life. Evetually though!

[Max Replica]

Nice work TK4013.
I'll try to check your measurements against mine soon (I'm curious if there is any variation on these). I'll also check the diameter of the big screw that's down in the round bottom part (that holds the stirrup on).

I should also mention that I've since made a few tweaks to my leg brace to make it even MORE accurate. I'll be updating my tutorial soon to reflect these small changes.

For one thing, I finally found a place that sells a slightly larger pop rivet that I think is more screen accurate (but it's only slightly different so it's really just for obsessives like me). For another thing, I managed to find a couple of more accurate buckles for the top straps. And I need to double check the width measurements I gave out for those top straps, I may have tweaked them just slightly.

So anyway, new photos and new details coming soon for the tutorial, but nothing earth shattering.

[tk4013]

No problem, that's why were all here