Death Lord Dummy - 1 -

   In the photo here (click to enlarge) you can get a good look at much of the items needed for the skeleton of your dummy. It is fair to note that the need for the PVC adhesive is purely to adhere the caps that cover the openings in each side of the hips assembly. This is not needed and can save you a few dollars off the cost of constructing this guy.

Included in this how-to are the full instructions on how to make your dummy animated with the addition of an oscillating fan motor. This element is purely secondary to the dummy's construction, as the fan in no way changes the construction of the dummy with the exception his pelvis would be a straight section of pipe instead of a T fitting to hold the base of the fan. So which ever way you choose to make yours, the body remains the same in dimensions and fittings with that single exception.

Here is a list of items with cut-out dimensions that you will need to build your very own Death Lord Dummy.

(1) Howard or Holmes brand 12" fan
(1) Head
(24) 5/16" x 3 1/4" eye bolts
(12) 3/8" x 1 1/2" course thread bolts
(48) 3/8" course thread lock nuts
(48) 5/16" flat washers
(12) 3/8" course thread lock nuts
(24) extra heavy, 1/2" cut washers
(13) 3/4" #8 pan head screws
(1) flat aluminum stock, 1/8" x 1/2" x 12" long
(2) 3/4" thick boards, 5" x 12"
(4) 1" PVC slip-on pipe caps
(1) can PVC adhesive

********1 1/2" PVC Pipe Fittings;*********
(5) "T" fittings; all female, all slip
(20) End caps; female
(1) "T" fitting with the center opening for 1" pipe
(2) 90 degree Elbows; all female, all slip
(4) 45o Elbows; all female, all slip
(2) Test caps; male (find in the ABS pipe section)

*********1" schedule 40 PVC pipe;*********
(2) 2 1/2" (hand)
(1) 17" (neck)

*********1 1/2" schedule 40 PVC pipe;*********
(8) 2 1/2" (shoulders, ankles)
(2) 3" (top chest)
(2) 4" (groin)
(2) 4 1/2" (upper arm)
(2) 5" (middle chest)
(2) 8" (fore arm)
(2) 10 1/4" (stomach)
(2) 12" (lower leg)
(2) 13" (upper leg)

   The first thing we will do is prepare your fan for service. You will begin by removing the cage & fan assembly and motor cover. You have likely heard that oscillating fans do not last when used to move the head or some other portion of an animatronic, especially when the fan itself has been removed. I have found that the secret to long life (5 years and counting) for your fan motor is ventilation. We are removing the motor cover so air can circulated around it for cooling and when we ultimately dress our dummy we will leave an opening at the top of the chest (through the neck) for the hot air to escape. Do these things and you should be as fortunate as I have. Also, note the brand and size of this fan is particular, as not all oscillating fans can be used in this fashion, as some, such as the Holmes 16" model has an integrated motor cover that functions as part of the working mechanism, so the cover simply cannot be removed. I found that there is some work to the cover since the on/off switch was wired after the cover was screwed on and the wires intertwine with the mounting bracket inside. To get this off I had to cut the back of the mounting bracket out to clear the wires for its removal. I then zip tied the switch, sans knob, to the other wires there on the top of the motor as tight as I could snug it in.