Project Bob Marley: Posey Gets a Better Joint

I hoped you like the previous Kestrel posts – always exciting when I can add a mark to the bird list.  It is also exciting when I can talk about a new revision in the Posey project.  The last time we delved into this addiction.. I mean project we were discussing the desire to add flexibility to the PVC structure (link here).  That resulted in revision V2.0 of the PVC Halloween Decoration Project.  If you recall, we leveraged eye bolts to create the joints in V2.0.  That achieved the desired ability to move the arms and legs into just about any position I wanted.  The issue is the structural stability of the eye bolts .. as in .. not that stable.  One long night on Pinterest (yeah, I said it) looking through board after board on the home haunting groups I discovered an excellent idea from someone that goes by Beelce on the Haunt Forums website (link here).  That idea looked like the perfect answer to my stability problem and immediately rushed out to Menards the next day.  Sure enough, they had 1″ chain link fence caps that matched the ones shown on the forum so bought every one they had – like 30 of them. After some trials and errors I am proud to present V3.0 of Posey!

NOTE: I did make some late updates to this model which I added to the end – please check that out since the modification uses less materials – that version is now being referred to as V3.1
Posey 3.0

This version is 100% more stable than the eye bolt approach and the joints work exactly the way I was hoping.  As with all my projects, let’s give some details.  Again, thanks to Beelce for providing the catalyst and the basis for even more versions – my  motto: embrace and extend.  First off, the hardware list.   Note, this version was built with chain link fence caps from Menards.  They hold a much better tolerance on their 1″ dimension but their connecting hole is 1/2″.  I recommend getting the fence caps from Home Depot instead.  They are a penny cheaper and have 3/8″ connecting holes instead so you save on hardware.  They do have a lot of variance in their 1″ dimension which oddly enough turns out to be an advantage in upcoming versions (more later on that).

  • Drill Press (technically optional, but highly recommended) if not, can uses a standard drill)
  • 1/8″ Drill Bit or whatever size fits the screws you are going to use to affix the chain link cap to the PVC
  • Pilot hole drill bit – smaller the better
  • Screwdriver – manual or electric to put the caps in
  • (16) Chain link fence cross bar caps w/ 3/8″ hole ($0.88)
  • (8) 3/8″ Large Washers ($3.78 – 100)
  • (8) 3/8″ x 1″ Bolts ($4.21)
  • (8) 3/8″ Nuts ($2.28)
  • (8) 3/8″ Split Washers ($2.00)
  • (32) 1″ cabinet, drywall or round head screws (use whatever you laying around that is in the 1″ long range)
  • Two Socket Sets
  • PVC Cement (optional)
  • Duct tape – preferably white
  • Hand PVC Cutter (optional, but highly recommended)

Next the materials list:

  • (3) 1″ PVC Cross ($2.15)
  • (4) 1″ PVC Caps  ($0.45)
  • (9) 1″ PVC T’s ($0.59)
  • (4) 1″ PVC Couplers ($0.41)
  • (10) 1″ PVC Elbows ($0.50)
  • (1)  3/4″ PVC Cross  ($2.37)
  • (1) 3/4″ PVC T’s ($0.45)
  • (5) 3/4″ PVC Elbows ($0.25)
  • (1) 3/4″ PVC Cap ($0.19)
  • (1) 1″ to 3/4″ Reducer  ($0.77)
  • (1) 10′ x 1″ PVC Pipe (depends on size but by two, if you are like me you’ll be making a lot of them) ($2.48)
  • (1) 3′ 3/4″ PVC Pipe (basically just enough to build the head) ($1.50)

Hit the jump to see how to build this version of Posey!

Continue reading Project Bob Marley: Posey Gets a Better Joint