Saluki Engineering Company
Proposal for:
Pumpkinhead Legs and Feet
To:
Mr. Patrick Novak
By:
SEC Team F11-81-Legs
Alexander Mireles (ME) (PM)
Christopher Petit (ME)
Michael Feltman (ME)
Elizabeth Holden (ME)
Faculty Technical Adviser:
Dr. Kambiz Farhang
Submitted on:
November 8, 2011
Transmittal Letter
November 8, 2011
Saluki Engineering Company
Southern Illinois University Carbondale
College of Engineering - Mail code 6603
Carbondale, IL 62901-6604
Mr. Patrick Novak
Dear Mr. Novak,
On September 9, 2011 we received your request for proposal for the design of legs and feet for the
Pumpkinhead costume. Attached is a proposal for the new legs and feet design to be used in place of the
current stilt system. We would like to thank you for giving us the opportunity to bid on this project and
appreciate your interest in these designs.
The proposed designs will improve upon the current designs implemented in the costume and create a
more safe, stable, and comfortable walking device. The designs will facilitate a better range of motion
and more stability than the current stilt system.
This proposal is based upon research of existing stilt and assisted walking designs and the current leg
and foot costume design.
Thank you again for the opportunity to bid on this project. We are looking forward to working with your
organization. If you have any questions regarding this proposal please feel free to contact us.
Sincerely,
Alexander Mireles
F11-81-Legs
Project Manager
amireles@siu.edu
Saluki Engineering Company
Executive Summary
The Saluki Engineer Company (SEC), team F11-81-Legs, proposes to design a new legs and feet system
for the Pumpkinhead monster costume. The proposal will designate three designs for the legs
subsystem, a design for the feet subsystem, and a design for the hip/waist subsystem. The criteria for
these designs are cost, size, weight, safety, mobility, and overall functionality.
The legs and feet designs model the monster from the 1988 movie Pumpkinhead. The dimensions of the
designs will fit the dimensions of the creature and allow the wearer to move with the costume. The legs
and feet must be designed to support the weight of the wearer and any additional costume features, along
with any forces that may be encountered in the event of a fall. The designs must also be light enough in
weight to be functional and prevent the instability that currently exists in the drywall stilt design.
The legs and feet designs will add a height of three feet to the wearer and allow for stable movement at
the elevated height.
The proposal will focus on three main subsystems: legs, feet, and hip/waist. The legs subsystem will
include three separate designs that will use the same feet and hip/waist subsystems. Autodesk Inventor
Professional and Ansys will be used to determine the stability and strength of the system before use to
prevent costs of building multiple prototypes and increase the safety of the design. Costs will also be
minimized by utilizing in-house manufacturing facilities and building the initial design using materials
with lower costs.
An initial cost for this design will vary depending on the leg design utilized. Assembly of the project
will begin on January 17, 2011 and be completed no later than April 5, 2012.
Non-Disclosure Statement
The information provided in or for this proposal is the confidential, proprietary property of the Saluki
Engineering Company of Carbondale, Illinois, USA. Such information may be used solely by the party
to whom the proposal has been submitted by the Saluki Engineering Company and solely for the
purpose of evaluating this proposal. The submittal of this proposal confers no right in, or license to use,
or right to disclose to others for any purpose, the subject matter, or such information or data, nor confers
the right to reproduce or offer such information for sale. All drawings, specifications, and other writings
supplied with this proposal are to be
returned to Saluki Engineering Company promptly upon request. The use of this information, other than
for the purpose of evaluating this proposal, is subject to the terms of agreement under which services are
to be performed pursuant to this proposal.
Table of Contents
Transmittal Letter (AM) ……............…….……………………………………………………... 2
Executive Summary (EH) ............................................................................................................. 3
Non-Disclosure Statement ……............………………………………………………………. 4
Table of Contents………………………………………………………………………………... 5
Introduction (CP) ...…………………………………………………………………………… 6
Literature Review .................................................................................................................... 7-10
Project Description (AM) ............................................................................................................10
Figure 1 ........................................................................................................................... 11
Basis of Design (AM) ................................................................................................................. 11
Subsystem Descriptions .......................................................................................................... 12
Hip/Waist Design (EH) ............................................................................................. 12-13
Leg Design 1 (CP) ...................................................................................................... 14-15
Leg Design 2 (AM) .................................................................................................... 15-18
Figure 2 ............................................................................................................... 16
Figure 3 ................................................................................................................ 16
Figure 4 ............................................................................................................... 17
Leg Design 3 (EH) ..................................................................................................... 18-21
Feet Design (MF) ....................................................................................................... 21-22
Project Organization (EH) .......................................................................................................... 22
Figure 5 ............................................................................................................... 22
Team Timeline (MF) .................................................................................................................. 23
Figure 6 ........................................................................................................................... 23
Action Item List (AM) ............................................................................................................... 23
Figure 7 ........................................................................................................................... 23
Resources Needed (All) ......................................................................................................... 24-25
References .................................................................................................................................. 26
Appendix A (Resumes) .......................................................................................................... 27-30
Alexander Mireles .......................................................................................................... 27
Michael Feltman ............................................................................................................. 28
Christopher Petit ............................................................................................................. 29
Elizabeth Holden............................................................................................................... 30
Introduction
The purpose of this project is to design a set of legs and feet for a costume of the monster from
the 1988 movie Pumpkinhead. The monster’s legs differ from human legs in that it has highly
exaggerated metatarsals (bones between the ankle and toes) and it walks only on its phalanges (toes)
rather than its phalanges, metatarsals, and calcaneus cuboid (heel). The proposed design will be an
improvement on an existing set of costume legs. These improvements include: improved balance, easier
and more functional locomotion, a greater range of motion for the wearer’s hips, an attachment point for
a costume tail, and motions that better replicate those of the monster from the movie thus making for a
more convincing illusion. This proposal includes three different subsystems: the hip/waist design, the
leg design, and the feet design. Currently, there are 3 separate leg designs. The proposed product will
include the hip/waist and feet subsystems as well as one of the three leg subsystems that will be chosen
Mr. Patrick Novak (herein after Client).
Literature Review
This Literature review will cover all of the subsystems of the stilt design including the stilt itself,
the hip/waist belt assist, foot pad, and materials of the stilts. It will also cover previous stilt designs and
reasons why they are not suitable for the costume.
The following U.S. patents were reviewed to find any similar designs: 822,448; 12,249,492;
6,648,803; 7,981,003; 7,374,514; 5,295,932.
Mr. Novak is currently using drywall stilts that follow the current designs in many of these patents. The
problem being that these stilts currently weigh far too much and the pad on the stilts does not allow for
much balance aside from being straight up and down. Some of the designs found have two part feet
allowing for some play in the foot bed which can help on uneven surfaces.[10 ][11] They still do not
have a large foot bed that is needed to accommodate our client’s large shoe. They are also not designed
to carry more than the weight of a person holding a sheet of drywall. Our costume will require the stilts
to be able to handle far more than the weight of the person due to Mr. Novak’s safety gear and the foam
rubber that comprises most of the costume. The weight will be factored in to the type of materials used
for the design and the actual leg and foot design used. Another design found has the four legged foot
look that we need to have for the costume since the creature is walking on its tiptoes and has more of a
dog or horse leg shape than a human shape.[3][2] Many of the designs found only really add a small
hoof or have used the human ankle foot to form a horse or cloven hoofed foot shape with a foot pad
added for realism and stability, however, these still do not meet the specifications needed of an almost 3
foot long foot which would cause balance problems on many of these designs. The forms of many of
these designs are also not the look desired the shape of an actual foot. Most of the current designs found
are far too small to match the scale of the Pumpkinhead monster. Stilt designs used in monster movies
and costume designs are on a much smaller scale. These designs can be helpful for an initial idea of how
to create our leg and feet mechanism, however, the ideas will need to develop these ideas further in order
to accommodate the large size and weight necessary for Pumpkinhead.[2][3][4]
Some designs of stilts
found that follow this more athletic and animalistic form is from the costume of the fictional Lycan
character from the Underworld films. The DVD’s for these movies have a behind the scenes feature that
show the design of the stilts are looking for. There was a company who was going to manufacture stilts
of these for public use but there were not enough per-orders and production was ceased. These stilts did
not quite meet our specifications for height so the design will need to be modified. Due to our modified
height requirements the angles of the legs will also need to be modified. The stilts will also have to be
strengthened so it is able to accommodate the weight of the costume.[5] A distributor of make your own
carbon fiber sheets were found for a reasonable price these would be a good way to encapsulate the stilts
linkages from getting clogged with foam rubber from the costume.[15] The shell will also help keep the
overall weight of the costume down since the gap between the shell and stilts will be an air gap and the
shell will be covered with foam rubber. Since the weight on the legs will be reduced it will be easier for
Mr. Novak to move around and appear more athletic when moving within the costume. Connecting the
outer shell to the legs and feet mechanism by using springs and cords will allow the shell to stay in a
somewhat stiff form, while still being able to move slightly to give the costume a more realistic look of
moving muscles and tendons that the creature may actually have.
Materials Selection:
Going to a home improvement store like Menards, materials are found for use as connectors for
the designs (i.e. bolts, screws, washers, springs, cords, etc.). This information is helpful in coming up
with ideas to construct the prototype out of cheap sturdy materials to test the initial design for motion
and stability. Using wood boards or aluminum may be a possibility for the prototype. They are relatively
cheap and durable materials that can test the design for motion and strength. Aluminum is also a good
possibility for strengthening the hip belt subsystem. Decreasing the weight of the final legs and feet
design will be dealt with from materials found using other sources. [6] Carbon fiber is a more expensive
material but is also strong and a very lightweight material that would be able to support the design and
protect the moving parts but also keep the mechanism at a light enough wait to allow for more ease of
mobility than the current design. This material however does not allow for the addition of brackets or
drilling holes very easily without sacrificing the entire piece [15]. Various materials can be used to add
some support to the material that are not crucial areas to strength but needed mainly for light stability
like polycarbonate rods. The rods have the strength necessary to add basic balance with a light weight so
they will not add large amounts of excess weight. They can give balance in areas where high stress is not
placed but the balance is necessary. [7] Using a steel composite for the final design build could cause
too much weight for the wearer to lift. Titanium and carbon fiber give good support to use as final
materials, however, the price would be a reason to look for other ideas for at least portions of the legs
and feet. Both materials are strong and lightweight when compared to steel or aluminum. Also, titanium
and carbon fiber are easily repaired. This could be a useful attribute after wear on the legs and feet when
repairs could be necessary. [8]
Hip and waist assist:
Honda has created a device that is an assisted walking device meant to help the elderly with
walking by taking much of the weight of the person and putting it onto an exo-suit like device. This
device was also designed with factory workers in mind that will help take much of the load off of the
person’s legs allowing for factory workers to work longer with less fatigue and chance of injury. This
has been a major concern of his since he will be wearing this suit for several hours at a time. The
design should incorporate a hip belt and possibly a seat system in order to help alleviate the weight off
of Mr. Novak. The belt system will need to take weight off of Mr. Novak’s back so that lower back
injuries do not occur. The mechanical assist design can be utilized to make the movement of the
costume more natural as well. Since most of the weight of the costume will be placed on the legs of the
costume it will require Mr. Novak to use less of his own strength to actually move the costume. A seat
in the costume could help Mr. Novak if he does become tired he will not have to search for a chair on
top of a table but he will actually be able to rest within the costume. A lockout system has also been
talked about with Mr. Novak so he can lock the stilts into place and he can rest while the stilts take the
weight of the costume.[1].
Feet and spring/shock assistance:
Springs have been decided to be used for the stilts due to their lower cost and ease of installation.
If Mr. Novak feels the need to have gas shocks they can always replace the springs at a later date.
Springs will give us the adjustability if more tension is needed to provide better balance. Springs will
also provide us with a very good range in a small package. Even car springs would be small enough to
fit onto our stilt design and the performance aspects far outweigh the needs of our project. The springs
will be used in several different places not only in order to help assist Mr. Novak with walking but also
helping him absorb the shock of walking and helping him balance on uneven surfaces. Uneven surfaces
have been a big problem for Mr. Novak because of the drywall stilts solid lower foot. So the foot pad of
new stilts will need to be able to articulate so that they can accommodate for uneven surfaces.
Project Description
The Pumpkinhead Legs and Feet are a leg extension/stilt device that will assist in the movement
of the wearer of the costume and improve the safety of wearer. Their main function will to be to improve
upon the current design, a pair of drywall stilts, and improve the safety and reduce chance of injury
while wearing the costume. The proposed limits of the stilts are (1) to mimic the scale of the original
monster as closely as possible, or do so in a manageable scale and (2) to be able to handle a minimum
load of 250lbs and stay steady. Also, safety features are to be incorporated into the subsystems in order
to minimize chance of injury to the wearer.
The leg extensions/stilts will consist of three subsystems as shown in Figure 1. The hip enclosure
will give the wearer a harness which increases safety by incorporating padding and other various safety
measures. These will attach to the leg supports at or near the hips to help eliminate any danger of the
legs straying too far apart and injuring the wearer. As requested, there are currently three separate
designs for leg supports, the final project design to be chosen at a later date. The leg designs include all
areas between the hip connection and the foot plate (where the wearer’s foot is positioned). The foot
plate is included within the leg designs while the foot pad (the base of the creature’s toes) is included in
the foot design. At the base of the leg supports are the feet. These will be designed to assist in balance
and improve the safety of walking on the stilts, as well as be aesthetically pleasing by giving the illusion
of realistic toe movement.
Hip Enclosure
(EH)
Leg Design 1
(CP)
Leg Design 2
(AM)
Leg Design 3
(EH)
Foot base
(MF)
Figure 1. Display of different subsystems.
Design Basis
The following documents provide the basis of design for the Pumpkinhead Legs and Feet for
Team #81 of the Saluki Engineering Company:
• Request for Proposal (RFP) September 21, 2011
• RFP Attachment 1: Project Definition September 21, 2011
• RFP Attachment 2: Design Report Deliverables Checklist September 21, 2011
• Team #81 Proposal November 08, 2011
The documents above are listed in order of precedence. In the event of conflicting statements in
design, the proposal will be the ultimate authority.
Subsystems
Hip/Waist
The main objective of the hip/waist subsystem is to create a comfortable, durable, and safe
connection to the leg subsystem and allow for stable secure movement within the Pumpkinhead
costume. Designs for the hip/waist subsystem will integrate a weight-lifting belt type of connection to be
secured around a wearer’s waist that will allow the leg subsystems to be connected and decrease the
amount of strain put on the wearer’s back and legs from lifting the legs and feet. This design will also
allow for the tail design from the F11-80-Tail team to be attached to the wearer. The hip/waist design
will have the general shape of a weight-lifting belt. Aluminum 6061 will then be secured to the back and
sides of the belt to create secure connecting points for the legs and tail subsystems.
Each leg will connect to the hip in two positions. Each leg will connect at the front of the belt
and the back of the belt by locking into place with a ball joint. This joint will be located just below the
wearer’s hip and allow for a range of motion between the legs and hip. However, this joint will still
maintain some restrictions on movement in order to keep the legs from moving to far away from the hip
or to close to each leg to prevent injuries. The hip/waist design will also include a feature similar to the
Hondo assisted walking device discussed previously. This feature would create an overall basket shape
for the hip/waist subsystem that would assist in relieving some pressure from the hips and allowing the
wearer to rest slightly on the cradle underneath the hip belt for a short time.
The hip/waist design will also include cushioning inside of the design to protect the wearer in
case of falling or other dangerous circumstances. The added safety equipment included inside the belt
will also decrease the amount of safety equipment needed to be worn while in the Pumpkinhead costume
and diminish the time necessary to put on the costume. The safety equipment will include padding inside
the hip/waist belt. The additional cushioning will create an increased girth for the wearer but which will
also allow for a more realistic waist size in comparison to the Pumpkinhead creature.
List of Deliverables

Allow for opening and closing of hips (range of motion for legs from hip area)

Safe, secure connection between wearer and leg subsystem

Accessible contact area for tail connection

Additional safety equipment attached to the inner portion of the hip/waist design

Engineering drawings of hip/waist subsystem

Fault analysis

Maintenance and repair instructions

User’s manual, including limitations, cautions, and instructions for putting on this part of the
costume
List of Activities

Design secure connection area for tail

Additional communication with F11-80-Tail team for information on final design
of tail and tail end connection necessities

FEA analysis on belt design with leg connections to insure strength of belt

Consult with the Craft Shop on material selection for the outer aesthetic layer

Design and build prototypes

Design and build final version, Client’s option
Leg Design 1
The purpose of the leg design 1 subsystem is to provide the wearer with the elevation and
appearance of a convincing monster, create a solid and stable connection between the waist/hip and feet
subsystems, and replicate the motion of legs with extended metatarsals. The subsystem will include
eight main parts (two sets of four parts, one set for each leg). The first part is a spring loaded stilt that
will compress to a fixed length under the weight of the wearer and extend to a greater fixed length when
the wearer lifts their leg off the ground. The spring will have a low spring constant value as it is not
intended to be used for locomotion assistance, but rather is only present to provide extension force and
compression resistance. This is the only load-bearing part of the subsystem and will attach to the wearer
at the feet and calves via a horizontal foot platform and strap while also making a solid attachment to the
feet subsystem. The second part is the monster’s metatarsals. This is a non-load-bearing part that will
attach to the top of the feet subsystem by a hinge as well as the bottom of the monster’s tibia (shin/calve)
also with a hinge. The third part is the monster’s tibia which is also non-load-bearing. In addition to
attaching to the top of the monster’s metatarsals, it will also attach to the bottom of the monster’s femur
with a hinge and to the spring loaded stilt with a pin joint. The location of the pin joint on both the
spring loaded stilt and the monster’s tibia will affect the apparent stance of the monster without affecting
the locomotion functionality of the subsystem. As such, it is considered an aesthetic choice and the final
position will be determined with input from Client. The final part is the monster’s femur and is also a
non-load-bearing part. It will connect to the waist/hip subsystem via hooks as while also attaching to the
monster’s tibia via hinge. The hinges and pin joint will create a bending of the monster’s knee, ankle,
and metatarsal-phalangeal joints when the wearer bends their knees and/or lifts the leg off the ground
causing the spring loaded stilt to extend.
List of Deliverables

Solid connection between the waist/hip and feet subsystems

Convincing monstrous appearance

Leg motion consistent with that of the Pumpkinhead monster

Engineering drawings of the above and the leg designs not used

Fault analysis

Maintenance and repair instructions

User’s manual, including limitations, cautions, and instructions for putting on this part of the
costume

Complete accounting for money spent, with receipts
List of Activities

FEA analysis on spring loaded stilt

Consult with the Craft Shop on material selection for the outer aesthetic layer

Consult with the client on location of pin joint that will provide the desired stance

Design and build prototypes

Design and build final version, Client’s option
Leg Design 2
Design 2 was designed to shift the weight from the wearer’s arch of their foot to the ball of their foot,
where it can be more easily handled. It must be able to hold the weight of the wearer while they are dressed in the
full costume and, above all, increase safety to the wearer of the legs. Design 2 was based off a digitigrade stilt, but
due to its height, modifications had to be made. Figure 2 illustrates the difference in digitigrade and plantigrade
legs.
Figure 2. The digitigrade animal, e.g. a dog or bear, has a much
differently shaped leg and foot than a plantigrade animal, e.g. a human . This shifts the weight from the heel/arch of the being to the ball of the foot.
Rather than setting the wearer’s feet on a plane parallel to the ground, digitigrade stilts angle the wearer’s foot and
extend the foot until it reaches the ground, giving the illusion of a large foot walking upon its toes, much like a
dog. As seen in Figure 3, this is exactly what the monster Pumpkinhead does.
Figure 3 demonstrates a digitigrade foot. The creature walked on the ball of
its foot as well as its toes, and its heel and ankle are located above the toe rather than parallel.
Designed with comfort of the wearer in mind, as well as ease of walking, Design 2 features springs and cables to
help with movement and keep the wearer from toppling too far over. The cables also help to provide a “resting
position” in which the cables are taught and hold the leg supports at a reasonable angle so the wearer can lean
against the built in supports to take their weight off of their feet and allow the supports to hold the weight for a
short time.
The upper leg/thigh supports are proposed to attach to the hips at a ball joint, located approximately 2 to 3
inches below the wearer’s hips, to increase mobility but still provide stability. The joints connecting the upper
and lower leg will be a limited hinge, allowing rotation on only one plane. Combined with the ball joint at the hip,
this combination closely mimics the human body’s natural movement, but still restricts the wearer’s movement
such as to not allow for too much freedom of movement that could lead to the wearer becoming off balance.
Material considered for this design is Acetal Resin. These materials present the best strength to weight ratio.
Current data yields that each stilt will weigh between 19 and 20 lbs, and easily support the weight of the wearer
and the costume.
Figures 4 below lists the features of the design.
Thigh support. Encloses the thigh of the
wearer. To feature padding inside of the
bars and rings to reduce chance of
injury. Attaches to the hip support with
a ball joint (not pictured).
Figure 4
Lower leg support. Features a solid rear
support to which cables would run from
the rear of the foot platform to restrict
movement past a certain angle, and
straps in the front to adjust to different
wearers.
Foot platform and foot extension. Foot
platform is featured at a comfortable
angle and balances upon the footpad at
the end of the extension.
List of Deliverables

Solid connection between the waist/hip and feet subsystems

Convincing monstrous appearance

Leg motion consistent with that of the Pumpkinhead monster



Fault analysis
Maintenance and repair instructions
User’s guide for putting on this part of the costume together with limitations and cautions for the
wearer
Complete accounting for money spent, with receipts

List of Activities

FEA analysis on stilt and supports with cables and springs.

Consult with the Craft Shop on material selection for the outer aesthetic layer

Consult with the client on location of cables and springs that will provide the desired stance

Design & build prototype

Design & build final version, Client’s option
Leg Design 3
Leg Design 3 must be able to support a minimum of 250 lbs in order to bear the weight of the
client and additional costume hardware. The foot plate (where the wearer’s foot is located), will attach to
the feet design at an angle that is parallel to the ground. The flat position of the foot plate will create a
stable surface for the wearer to walk on and diminish the chance of slipping. The client has voiced
concerns of foot discomfort in the current Pumpkinhead leg design. To counteract this discomfort,
additional cushioning will be included in the foot plate to increase comfort and also create a dampening
effect while walking within the device. Additional recommendations to decrease discomfort would be to
use ski boots while wearing the Pumpkinhead costume. These shoes will increase the amount of support
to the wearer’s feet while also giving additional cushioning considering these types of shoes are
designed for rough terrain and intended to be worn for extended periods of time. The braces of leg
design 3 will be made of acetal resin. This material has compression strength that is high enough to
withstand the minimum weight requirements and light enough for the wearer to be able to move without
extreme difficulty.
The lower leg will include a metal brace along the inner and outer portion of the leg. These
braces will be connected by a front cover over the shin and two re-sizable straps across the calf. The
straps will allow the wearer to change the size of the back end of the lower leg of the design to insure
that the wearer’s leg is secure within the device. The front brace will allow the wearer to lift the lower
portion of the leg and will also include additional padding to prevent injuries while walking within the
costume. The upper leg (thigh portion) will be designed in a similar manner to the lower leg. The upper
leg will contain connecting points to connect to the hip/waist portion of the design. The upper and lower
portions of the leg design will connect using a hinge joint that will allow for the leg to move in a
walking pattern. This hinge joint will not allow for movement to go in all directions. The ball-joint
connection between the upper leg and hip creates the necessary motion needed to change directions
while walking, while the hinge joint between the lower and upper leg will only allow for forward and
backward motion. The restriction placed on the connecting joint between the two leg portions will create
a more stable walking motion and will restrain the costume from turning in a dangerous direction at the
knee joint. This will create safer movement while wearing the design.
The monster leg will be supported using pvc-piping. The monster leg is not supporting extra
weight in addition to its own weight which allows for a lighter, cheaper material to be used to construct
the design. Each monster leg will attach to the toe portion of the foot plate and again at the top of the
hip/waist subsystem. The faux leg will be divided into two portions, similar to the wearer’s leg design,
and be connected using a hinge joint at the knee. The resting position of the monster leg will create the
angle of the athletic stance of Pumpkinhead as shown in Figure 3. This position will also correspond to a
comfortable, slightly angled position of the wearer. This position will be at the discretion of the client
and dependent on the angle of the knee in a comfortable, slouched stance. As a result of the large ratio
between the size of the wearer’s legs and Pumpkinhead’s legs, changes in angle of the wearer’s legs will
only cause slight changes in the angle of Pumpkinhead’s legs. This will allow the creature legs to
consistently appear in a more athletic stance even if the wearer is standing with little to no knee angle.
Connected to the monster leg will be additional pvc-piping. This piping will be attached to the
monster leg to create an outer casing that will create a 75% of the cylindrical encasing around the
monster leg. The uncovered 25% will be positioned directly over the wearer’s leg. The uncovered
portion will allow the wearer’s leg to partially hide within the encasing to create a more aesthetically
pleasing monster costume. The majority of the pvc-piping will be connected using dowel rods to create
secure connections. In addition to the securely connected piping, a small portion of the piping will be
connected using slightly stiff springs. The springs will allow for slight movement while the wearer is
walking. During each step, the spring will cause the piping to move slightly which will cause the
appearance of moving muscles on the creature’s legs. The entire casing will be covered in an outer
aesthetic layer that will be selected by the client and the SIU Craft Shop to create a more realistic
looking monster.
List of Deliverables

Solid connection between the waist/hip and feet subsystems

Convincing monstrous appearance

Engineering drawings of the above and the leg designs not used

Leg motion consistent with that of the Pumpkinhead monster

Fault analysis

Maintenance and repair instructions

User’s guide for putting on this part of the costume together with limitations and cautions for the
wearer

Complete accounting for money spent, with receipts
List of Activities

FEA analysis on stilt and supports

Consult with the Craft Shop on material selection for the outer aesthetic layer

Consult with the client on desired stance

Design & build prototype

Design & build final version, Client’s option
Feet
The foot pad of the monster is a main focal point in the project. The current stilt foot pad is
around the size of a size ten shoe and just as wide. This needs to be changed so that the silts have better
balance under the weight of the costume. The foot will have articulating toes so that it is more stable for
the wearer while on uneven surfaces and rough footing. The foot pad will be covered with a slip
resistant coating to give the wearer more safety on slick surfaces. The foot pad needs to be sturdy
enough to handle the load of the costume wearer but still light enough as to not impede movement. The
linkage from the foot pad will have to be sturdy enough to handle most of the weight of the costume
wearer but it needs to move just slightly as to give a lifelike motion. The main purpose of the foot pad is
balance, stability, lifelike motion.
List of Deliverables:
1.
Specifications of foot pad
2.
CAD drawings of the foot pad
3.
Articulating toes and ankle joint
4.
Estimated Spring Strength needed
5.
Full Scale Prototype
List of Activities:
1.
Expand foot pad design to be closer to the size of the foam rubber covering
2.
Design toes to have movement enough to create balance but still resemble a living
creature’s foot.
3.
Perform FEA on foot and toes to make sure that the design will be able to handle stresses
of being walked on.
4.
Compute Amount of spring force required for motions need and for safety.
5.
Determine foot pad bottoming in order to prevent slippage on floors but durable enough
to last.
Project Organization
Client: Mr.
Patrick Novak
Faculty Technical
Adviser:
Dr. Kambiz
Farhang
Alexander Mireles
Project Manager
Mechanical Engineer
Leg Design #2
Figure 5. Project Organization
Christopher Petit
Mechanical Engineer
Leg Design #1
Michael Feltman
Mechanical Engineer
Feet Design
Elizabeth Holden
Mechanical Engineer
Hip/Waist Design and
Leg Design #3
Team Timeline
Activity
Verify specifications
Test subsystems
using computer
programs and/or
hand calculations
Build & test
prototypes
Design Reviews
Order parts
Build Subsystems
Progress Report
Perfect subsystems
Assemble device
1st System Test
Prefect device
Poster Due
Document Design
16-Jan
23-Jan
30-Jan
6-Feb
13-Feb
20-Feb
27-Feb
5-Mar
12-Mar
19-Mar
26-Mar
2-apr
9-apr
16-apr
Figure 6
F11-81-Legs Spring 2012 Action Item List
#
Activity
Person
1
FEA Drawing for Design 1
2
New
Due
Assigned
Due
CP
12-Dec
17-Jan
0%
FEA Drawing for Design 2
AM
12-Dec
17-Jan
0%
3
FEA Drawing for Design 3
LH
12-Dec
17-Jan
0%
4
Prototype building for feet/hips
MF
12-Dec
17-Jan
0%
5
Material Testing for Design 1
CP
12-Dec
17-Jan
0%
6
Material Testing for Design 2
AM
12-Dec
17-Jan
0%
7
Material Testing for Design 3
LH
12-Dec
17-Jan
0%
MF
12-Dec
17-Jan
0%
8 Material selection for feet/hips
Figure 7
Status
Resources Needed
Item
A
1
2
3
Description
Computer and
Software
Computer
Autodesk
Inventor
Ansys
Computer and
Software Total
Quantity
$ each
1
1
on hand
on hand
1
on hand
$ for Quantity
Subtotal
$0.00
B
1
2
C
1
2
3
4
5
6
7
8
1
2
Hip/Waist
Subsystem
Weight lifting
belt
Aluminum 6061
– ½ x 24 x 48
(in)
Hip/Waist Total
Leg Design 1
Subsystem
2” OD{A} x
1.750” ID {B} x
.125” Wall {C}
Tube 6061
Aluminum 18”
1-3/4” OD {A}
x 1.500” ID {B}
x .125” Wall
{C} Tube 6061
–T6 Aluminum
18”
¼” 6061-T651
Aluminum Plate
12”x24”
LHC 2075 085
(spring, free
length 6” solid
length 3” spring
constant 68.73
lb./in)
½ x 3 Universal
Adjustable
Clevis Pins Qty
(10)
DragonPlate
Carbon Rod –
0.25” x 48”
½ Flat Washers
USS (1 lb.)
hooks
Leg 1 Design
Total
Leg Design 2
Subsystem
Acetal Resin
sheet – ½ x 24 x
24 (in)
Various springs,
bolts, cords,
screws, etc.
Leg 2 Design
Total
1
$40
$40
1
$166.06
$166.06
$206.06
2
17.97
15.94
2
8.54
17.08
2
36.11
72.22
2
28.37
56.74
1
26.40
26.40
6
11.25
67.50
1
on hand
4
on hand
$255.88
+Shipping
1
$106.00
$106.00
$50.00
$50.00
$156.00
1
2
3
4
1
2
3
4
Leg Design 3
Acetal Resin
sheet – ½ x 24 x
24 (in)
PVC – piping
½” diameter 10ft
PVC – piping
1/4” diameter –
10ft
Various springs,
bolts, screws,
etc.
Leg 3 Design
Total
Feet Design
Acetal Resin
sheet – ½ x 12 x
24
Acetal Resin
sheet – ½ x 24 x
24
Acetal Resin
sheet – 1 x 12 x
24
Acetal Resin rod
– 3” diameter 7
ft.
Feet Design
Total
1
$106.00
$106.00
1
$4.20
$4.20
1
$5.20
$5.20
$50.00
$50.00
$165.40
1
$53.00
$53.00
1
$106.00
$106.00
2
$70.00
$140.00
1
$199.50
$199.50
$498.50
Highest Total
for Design
Leg Design 1
+Feet + Hips
$960.98
References
[1] Staff Writers, "Honda unveils leg assist machine for elderly,"
http://www.spacedaily.com/reports/Honda_unviels_leg_assist_machine_for_elderly_999.html, Space
Daily, Nov 7, 2008. [10/1/11].
[2] W. Segerman, "Alien Costume," www.willsegerman.com/alien_costume.html, Things I Do, website,
Jan 2007. [IEEE] Available: . [Accessed:09/28/11].
[3] Selena, "Satyr Costume Stilts," http://musesofsaberwind.blogspot.com/2010/02/satyr-costume-stiltsbeginning-thought.html, Muses of SaberWind, website, Feb 7,2010. [IEEE].
Available:http://musesofsaberwind.blogspot.com/2010/02/satyr-costume-stilts-beginning-thought.html.
[Accessed: 09/28/11].
[4] M. Bard, "Hoof Stilts," The Horse Tail-or,
http://transform.to/~mwbard/stuff/thehorsetailor/indexhoofstilts.htm, 2010. [IEEE]. Available: .
[Accessed: 09/26/11].
[5] Ozgosh, "Underworld Lycan costume," www.thehunterslair.com/topic/12652-underworld-lycancostume/page_st_25_p_144323#entry144323, Forum, 07 Jun 2009. [IEEE]. Available:
thehunterslair.com. [Accessed:09/29/11].
[6] "Menards"
www.menards.com, [Online]. Available: internet address. [Accessed: 9/28/11].
[7] “K-Mac Plastics” http://k-mac-plastics.net/index.htm [Online] [Available] k-mac-plastics.net
[8] ”Cal Fee Design” http://www.calfeedesign.com/tech-papers/technical-white-paper/ [Online]
[Available] www.calfeedesign.com
[9]A. Hanson. “Spring Stilt.” US Patent 822,448, June 5 1906.
[10]Rowan. “Stilts” US Patent 5,295,932, Mar. 22 1994
[11]J. Jay. “Stilts.” US Patent. 6,648,803, Nov. 18 2003
[12]Z. Jaconson. “Rear Brace Articulating Stilt” US Patent. 7,981,003, Jun. 19 2011
[13]T. Anderson. “Economical Foam Stilts” US Patent. 7,374,514, May 20 2008
[14]R. Singleton. “Walking Stilts with seperate heel and toe sections.” US Patent. 12,249,492,
[15] “Protech Composites” www.protechcomposites.com, [Online] Availible: [Accessed:9/28/11]
Appendix A –Resumes
Alexander Mireles
amireles113@gmail.com
Permanent Address:
College Address:
22117 Woodbine Road
Richton Park, IL 60471
(708) 712-2371
400 W Oak St
Carbondale, IL 62901
(708) 712-2371
Objective: Gaining real world experience and expanding my knowledge in the mechanical engineering discipline.
Professional Summary

Secretary of ASME
Education
Bachelor of Science in Mechanical Engineering, May 2012
Southern Illinois University, Carbondale, IL 62901
GPA: 2.7/4.0
Relevant Coursework
 Mechanical Engineering Dynamics
 Mechanics of Materials
 Engineering Thermodynamics I & II
 Finite Element Analysis in Computer Aided Drafting
 Machine Design
Experience
Clerical & Office Related, SIUC College of Engineering Dean’s Office January 2011 - Present
 Provide office support to the administrative staff.
Site Supervisor, Richton Park Parks & Recreations May 2008 - Present
 Maintain/Service all 16 parks, as well as mechanical upkeep of Community Center
 Repair any damaged equipment at any location.
Skills




Windows Operating systems
MATLAB
Microsoft Office Software
Proficient with repair equipment, i.e. hand tools, power tools
Honors/Awards

SIUC College of Engineering Dean’s List student, December 2008/May 2009
Activities

Student member/Secretary, ASME, Southern Illinois University Carbondale, September 2008 - Present
Michael Feltman
feltmanm89@gmail.com
School Address:
Before 5/7/2012
400 W. Oak
Carbondale, Il 62901
(708) 502-5700
Permanent Address:
After 5/7/2012
50 N. Ashland
LaGrange, IL 60525
(708) 502-5700
Objective:
To obtain an entry level job in Mechanical Engineering with a preference in internal
combustion engine design
Education:
2008-Present: Southern Illinois University Carbondale
B.S. In Mehanical Engineering, May 2012
Classes:
Internal Combustion Engines, Chemical Thermodynamics, Thermodynamics, Heat
Transfer, Machine Design
Experience:
4/2011-present Walker's Bluff
Carbondale, IL
Some job responsibilities included helping customers decide what type of wine they
would like to drink based on their preferences, valeting cars for customers at the
restaurant on property and helping out in the vineyard when extra staff was needed.
8/2009-10/2009
Booby's Sandwich Shop
Carbondale, IL
Some job responsibilities included making sandwiches for customers, checking I.D.s at
the door to make sure people were of legal drinking age, cleaning up the shop at the end
of the night after the shop was closed.
Interests:
Internal combustion engines: diesel and gasoline, Heat transfer, design.
Activities:
ASME
Awards:
Eagle Scout Awarded in 2006
Christopher Petit
Chris.r.petit@gmail.com
Address:
514 East Taylor st.
Benton, IL 62812
(708)217-1440
Objective:
To bring innovative solutions from conception to implementation in a thorough and efficient
manner.
Education:
Bachelor of Science in Mechanical Engineering, December 2012
Southern Illinois University Carbondale, IL 62901
GPA: 2.1/4.0
Experience:
Delivery Driver, Dominos Pizza (January 2009-Present)
 Provided excellent customer support
 Delivered food in a timely and efficient manor
 Performed cleaning duties and general building maintenance
Foreman of Balcony Repair, Riviera in Palos Improvement Association (Summers June 2001-August
2008)
 Oversaw the inspection, repair, and replacement of balconies in a four hundred and seventy two
unit townhome complex
 Coordinated and oversaw a three man crew
 Performed general building maintenance and landscaping
 Met weekly quotas
Skills:



Autodesk Inventor
Microsoft Office
Autodesk AutoCAD
Honors/Awards:



PSAE All-Star Award, 2003
Recipient of State of Illinois and SIUC academic scholarships, 2003-2005
Dean’s list, Fall 2005, Spring 2011
Activities:

Event Coordinator, SIUC Redliners Motorcycle Club, June 2008-June 2009
Elizabeth Holden
lholden1990@gmail.com
Permanent Address:
850 Tunnel Lane
Anna, IL 62906
Objective: Obtain engineering experience that could lead to a job.
Education
Bachelor of Science in Mechanical Engineering, May 2012
Southern Illinois University, Carbondale, IL 62901
GPA: 2.9/4.0
Experience
Student Worker, Academic Scholarships Office August 2008 – Present

Organize annual interview date

Oversee everyday office operations

Direct students to important information
Skills

AutoCad, Inventor

MATLAB

Microsoft Office Software

C++, JavaScript, and HTML coding

Adobe Professional
Honors/Awards

SIUC College of Engineering Dean’s List, December 2008/Summer 2009

PKP Sophomore Scholarship May 2009
Activities

Member, SWE, Southern Illinois University Carbondale, August 2008 – May 2011

Member, SUMMIT, Southern Illinois University Carbondale, August 2010 - Present