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How to make a DIY Mannequin with Duct Tape Body and PVC Frame

This How-To DIY Video is directed at Mannequin Builders

John, our Stun Dummy Double with articulating joints(Double Ball), Duct Tape Skin, Resin Head Cast, and PVC Frame. The Tulsa Video Magazine'"s concept is to create a website that reaches out to all of Tulsa and surrounding areas and bring them together to find out everything there is to do locally. Its intent is to reach Tulsans with activities such as, Clubs and Organizations,(I.E. Chess, Table Tennis, DIY crafts, Knitting, Tennis, Soccer, Football, Flag Football, Recreational Sports, Ultimate Frisbee, Disc Golf, etc.), free events, places of interest, and talent that is otherwise unheard of and display them in a creative manner. The Dummy idea spawned after Gabriel (Owner of Tulsa Video Magazine) had been performing some acrobatic features and Troy thought it would be funny if he messed up really bad. But how could we do that without hurting Gabriel in the process?

Our Stunt Dummy was then thought of and we thought to ourselves, well what if others would be interested in the creating something of the same stature. So we decided to video the process to show him off to the world. And then it dawned on us, we could use our own website to promote ourselves and be our first customers. It was the perfect test subject. So we documented all of our steps, threw john in a test video and then put him on our own website to see if we could use him to jumpstart our process. Quite frankly, if you'"re viewing this page and reading this far it has been a major success. We intend to use John in as many videos as possible to bring laughter and joy about the talents available in Tulsa. He is the perfect Stunt dummy because of how we made his articulating joints. Which the idea for the articulating joints is a concept that we hadn'"t ever heard of. A double ball joint for his Arm Sockets, Shoulders, Hands, Feet, and Knee caps was the first in existence. We have made several to his joints since the publication of this video which are all labeled out in the icons above this video.

Our Stunt Mannequin is the first in existence to have a double ball joint for his Arm Sockets, Shoulders, Hands, Feet, and Knee caps.

In our Articulating Joint update we carefully go over each detail we took to create this joint. Including sizes and parts used that are necessary for our creation of this piece. It is slightly different creation than this video as we add a double ball instead of just a singular ball. This mannequin is very unique and we plan on making several changes in the near future. These updates will be added to our mannequin page here if you are interested in being a part of our updates to the mannequin or have an idea that you would like for us to try please contact us at the top via email, phone call or text and we will be happy to get you on board with our team. Also we are always looking for new and innovative ideas to add to the Tulsa Video Magazine experience. We would love for a new idea to be presented that we could collaborate and work on as a community. Feel free to submit any idea you have for ANY type of mechanics, Park Renovation, Tulsa ANYTHING.
We also show how we wrapped his Skin with Duct tape for this PVC Stage Prop Creation

Although his insides don'"t look anything like Gabriel the owner of T.V.M. all of the dimensions for John, we decided to give our stunt dummy a name, all of his dimensions were taken and drawn from Gabriels heights and weights so that he would seem more realistic. Even his skin, or body armor was first put on Gabe to make the outter layer of John more realistic. His armor is made completely out of black and some grey duct tape and constructed first by wrapping Gabe in it, carefully cutting it loose from him and then stuffing it with things like, cotton pieces. We also decided to use a hardened foam base to fill his legs and arms to the same widths and lengths that Gabriel also has on his own body. This process was a very interesting one and great for learning how your body works it's not too difficult and is great fun for children to create this cheap mannequin. I would recommend it if you child is in to mechanics as well as athletics, it really shows you the range that your body has and how you can use your body to its extents without harming the insides.

Finally, there are no words that can describe the amount of help we are getting from our viewers, each and every view we get is a fundamental achievement that we have for our magazine, the more this video is shared and liked by everyone the more we get out of it. I would like to take just a minute and thank each and every person that has been to our website from YouTube, shared the video, liked the video. You guys are awesome.

Below are the comments we have received about this video Thanks again, Enjoy

Tejaswini Tejaswini1 month agoHighlighted comment Hi, this is great stuff, exactly what I was looking for and I have few questions if you could help me, please. Is that 32 mm waste pipe? What sort of socket plug is that? I need to attach and articulated hand like this https://www.amazon.co.uk/d/Arts-Crafts/BQLZR-Artist-Articulated-Mannequin-Wooden-Manikin-Drawing/B019SUVD2Q/ref=sr_1_1?ie=UTF8&qid=1497216686&sr=8-1&keywords=articulated+hand. Can you help this will be strong enough to hold the weight of this hand and stick to a position that is set? Please help Tejaswini Tulsa Video Magazine Tulsa Video Magazine1 month ago Do you know the weight of the hand that you're wanting to attach to the joint? It's unlikely that the way we have the mannequin set up, it wont be strong enough to hold something that weighs more than 1 LB. The diameter of the PVC pipe we used is 1 and 1/4 Inches. I'm not positive of the ratio to Millimeters. Tulsa Video Magazine Tulsa Video Magazine1 month ago Hi Tejas, I will speak with the designer and get back with you ASAP! Tulsa Video Magazine Tulsa Video Magazine1 year ago zbyszekroyal, The bolt head should be burried until the head is flush with the outside of the ball. If you stick it further into the ball it wont necessarily make a difference, but when compressing the ball it could split the ball, so going too far will cause issues. We used 3-1/2" Bolts and ground off the extra length with our bench grinder. The slot is so the joint can articulate further not for keeping the ball in place. We used hose clamps to adjust the joints rigidity after compressing the clamp with our hands. Also, when you are compressing the ball into the socket be sure to use a towel and some water to compress the coupling around the ball while it's still warm, this is what will lock the ball into the socket above everything else, the hose clamp is just for insurance and to keep the joints from moving around on you. Lastly, if you didn't want to use a coupling, you could use 1-1/4" PVC and just pound the balls in directly, this will work the same way as having a coupling on 1" PVC. Just an FYI! Any other questions or do I need to elaborate on anything. Let me know! Zbyszekroyal zbyszekroyal1 year ago Thank you so much for the prompt and detailed reply! You rock!! However, I'm thinking the 3-1/2" bolt is for the double articulation. I've decided that the only double articulation I want is for shoulders and perhaps one or two other joints. Seeing how my 2" bolt was too short and I had to pull it into the golf ball another 1/2 inch, and judging by what the bolt looked like when you held it up to the camera, I'm thinking the single-articulation bolt is 2 1/2". Am I right? And one more thing: why didn't you cut two slots into the coupling instead of having two golf balls? Would two slots be too compromising of the coupling's integrity, and cause it to break? Thanks!!! Zbyszekroyal zbyszekroyal1 year ago On, one more thing. I have all the tools I need except for…… the bench grinder. Any ideas here? Tulsa Video Magazine Tulsa Video Magazine1 year ago +zbyszekroyal Single articulation is yes 2.5" bolts, also, if you bought the bolts at a hardware store, generally they will exchange them just a helpful hint. The more you cut the coupling the less rigid your structure so to answer your question we found that adding an additional ball to the socket was a lot better for rigidity than cutting the coupling up. The reason for the two-balled joint is to allow rotation on one half, and then horizontal and vertical movement on the other. If you don'"t have access to power tools it's possible to use a Hack Saw to cut the bolts off, However this will be a very slow process and they wont be flush, which you could use a file to get them as close to flush as possible. The joints will still rotate, the issue is that the bolts will only rotate until they hit the inside of your coupling, stopping rotation. It's not completely necessary for the inner hip joints or shoulder joints to have a completely flush bolt, you will still get some rotation depending on how much excess bolt you have. The less bolt, the more rotation. Zbyszekroyal zbyszekroyal1 year ago You da man (assuming you're Gabe)! Actually for all I know, you could be da men and da ladies! Thanks to everyone who's helping me! Tulsa Video Magazine Tulsa Video Magazine1 year ago hahaha You're welcome bud. Good Luck, if you come up with any differences you'd like to share feel free, this was our first prototype and we just cracked down on it until we got it to work. Always looking for new ideas and projects. Zbyszekroyal zbyszekroyal1 year ago Hi. Me again. I have tried five times making the joints…. I cannot get the ball to "lock" inside. It falls out just by inverting the joint. Each time I tried a different length of the slot. Nothing worked. And I don't have a heat gun, I am using a propane torch. Any advice? It's crunch time over here; I need to have this done this weekend and here I am not even having started. Tulsa Video Magazine Tulsa Video Magazine1 year ago +zbyszekroyal When you are putting the golf ball into the Socket, you have to apply a very large amount of pressure, we hammered it in, there is a very small ring on the inside of the coupling, if you look closely. If at all possible the golf ball should be almost touching that ring. So, my suggestion is to reheat the socket, and try and get your ball further into the socket. This is what will help "lock" your joint. Also, before the socket cools down wrap a towel or something to stop your hands from burning and squeeze the top of the coupling to attempt to mold the joint around your golf ball. After doing so you will have to "Break" the ball loose from the socket, do not do so until the socket has hardened again(cooled down). This is the exact method we used(Other than the propane torch, however the method of heating your socket shouldn't have much of an effect on its outcome). If you still can't get it, maybe you could send me a picture of your work and I'll try and see if I can visually explain it based off of what your situation is like. Good luck! Zbyszekroyal zbyszekroyal1 year ago Thanks. What do you mean by "break the ball loose"? Tulsa Video Magazine Tulsa Video Magazine1 year ago Well when you heat the coupling up enough, the ball will melt a tiny bit into the coupling which is fine, but again you will have to break it loose. Inside the socket before you'll get rotation out of it. It shouldn't come completely out of the socket, just give you articulation afterwards. Zbyszekroyal zbyszekroyal1 year ago Got it, thanks. Zbyszekroyal zbyszekroyal1 year ago I was going to describe my success to you and post accompanying photos, but this has been a heck of a learning curve with more than a few unexpected problems. The latest is this: The joints were really tight when I made them, but once I assembled and glued the whole frame, they got really loose. The hose clamps hold the balls in place, but the issue is that the joints spin on the nuts. The balls stay stationary in the PVC fittings while they spin on the nut! It's worse for the double-ball joints. Help, please. Tulsa Video Magazine Tulsa Video Magazine1 year ago In our experience We have had success in tightening loose joint in this manner. If the bolt is still securely imbedded in the golf ball and not completely striped out of the ball you may be able to tighten it up by pulling on the joint like you are trying to pull it apart and spinning it in the direction that would normally tighten the bolt, be care full not to over tighten. When posing the dummy the clamps should be loose enough to not break loose the joint bolts.Posing while they are tight in the manner described will result in some kind of failure of the joint. Take care not to over tighten the clamps until you have the dummy in the pose you desire.If a joint becomes striped out you have to replace it or take the joint apart and get a wrench back on it. We have replaced many pieces on our dummy by cutting out a joint and replacing it.It will generally cost you a pvc coupling to repair a joint. If you are trying to support a lot of weight with the dummy such as heavy clothing and the like then you might consider increasing bolt size as this gives you more surface contact with the golf ball's outer plastic and tends to hold weight better. We recently replaced most of our joints with the three eights bolts to better handle the weight of winter clothing. Hope this helps. Let us know how its comes out. Zbyszekroyal zbyszekroyal1 year ago It would have been nice if you had said this from the get-go. I'll keep trying to work out something to fix it. In the meantime I have added supports to it to help it stand. I am thinking my next mannequins will not have any double-articulations. That abdomen joint is quite problematic. If you wish to see photos of what I've accomplished with your guidance, check out my facebook page….. Mark C Still. Zbyszekroyal zbyszekroyal1 year ago Maybe something like Loc-Tite or a thin coat of epoxy.something that will hold the joint in place but can be broken with leverage. TheMrarthas TheMrarthas1 month ago Tulsa? That'"s my hood!!! 918 all the way Manutahi Mairau Manutahi Mairau7 months ago bro , you are a genius !!!!!! Mauururu ( thanks ) !!!!! Paul Elias Paul Elias5 months ago Just wondering if you have a parts list available ? - eg. Number of specific items used, sizes, widths, lengths of items used etc…. Chivone21 chivone218 months ago 'OLY CRUNCHY TOENAILS BATMAN !!!!!! Devin Doull Devin Doull9 months ago I'm guessing u used 1 inch Devin Doull Devin Doull9 months ago What inch pvc pipe do I use for the dummy, I tried to use 3/4 inch pvc for it but it seems to small and the golf ball is to big for the 3/4 inch connecter Tulsa Video Magazine Tulsa Video Magazine9 months ago Remember to heat up the ends so that you can insert the ball in. Without that process the ball will not fit in the 3/4 Inch hole. We used 3/4 Inch PVC. Devin Doull Devin Doull9 months ago +Tulsa Video Magazine I went back to it again today and it all worked thank you for the help, I will update u on my guy and how it all goes Tulsa Video Magazine Tulsa Video Magazine9 months ago Awesome, sounds good and good luck! Thomas Walton Thomas Walton6 months ago in your comment above you said you used a coupling on 1" pvc. But here you said 3/4" pvc. Which did you use? Tulsa Video Magazine Tulsa Video Magazine6 months ago 1" PVC is used all throughout our creation, we started with 3/4" PVC all around and had to do a large amount of heating and the balls were a bit hard to insert. Use 1" for the best fit for all pieces of PVC on the design. Thomas Walton Thomas Walton6 months ago Are the joints stiffer using a coupler for 3/4" than a 1" coupler Tulsa Video Magazine Tulsa Video Magazine6 months ago If you can manage to insert the ball into the 3/4" coupler then yes they should be stiffer, since it's a smaller hole. However if you melt too much of the PVC it will lose some of it's rigidity So take care when doing that. My suggestion is to use the "Beam clamps" to increase stiffness if you are having an issue with that. Fun halloween stuff fun halloween stuff9 months ago brilliant! GummyTumor GummyTumor10 months ago This is pretty incredible. Thanks for posting, I'm gonna try to build this, but I need to save up for some of the tools first. Tulsa Video Magazine Tulsa Video Magazine10 months ago Awesome! It would be great to see your rendition of it and keep us updated on your progress. Always love another DIY person. Good luck! Tim McKinney Tim McKinney1 year ago I have that same cap on the chair. Small World. Lol Cap Props Cap Props1 year ago Thanks a lot for this video I plan following up and making one for myself soon for my armor cosplays. I really hope if helps fills the needs im after and ill be sure to post a message saying thanks for tutorial u guys did. And again thanks for sharing Tulsa Video Magazine Tulsa Video Magazine1 year ago +Cap Props Thanks a lot, Would love to see what you come up with afterwards. Keep us updated and good luck. Keith Cassidy Keith Cassidy1 year ago With the 1-1/4 inch PVC do you still have to heat the PVC Tulsa Video Magazine Tulsa Video Magazine1 year ago Yes you will still need to heat the PVC. We have found that a heat gun works the best for the heating. The heat allows the PVC to wrap around the ball giving you a secure fit without the secure fit the ball will just pull out with no resistance. Keep in mind that this is the way we did our build. If you find a more creative way to do it we would like to here about it. Our goal in putting out this video was to get people thinking about ways to make the mannequin have full mobility like a human thus giving it a more life like appearance. This was the only way we found to do it affordably it is not necessarily the best way. Zbyszekroyal 1 year ago Hi! Regarding your PVC mannequin. This is fantastic and I will make this myself. I purchased all the parts and started this morning. But it seems I bought too-short bolts. You don't mention this on the video. I bought 2-inch, and the only way they work is if I suck the bolt head about 1/8 inch or more into the golf ball. But that won't make a difference will it? Also, for the double-articulated joints, how long are those bolts? I went ahead and heated the coupling and pounded the golf ball in without dremmeling the slot first. So, right now the golf ball is loose. Is it that slot that allows the ball to lock into place? I am hoping you will reply back ASAP. I need to make this mannequin - and possibly more - for a Thanksgiving/Christmas display this weekend! Thank you, Mark

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