3-Axis Skull Mod for 12ft Skeleton

Description

I've been in the world of Halloween based animatronics for over 10 years and have even made a name for myself with my MonkeyBasic software, now available through https://LifeApe.com.

So it only made sense that once I got my hands on one of these that I would cut it open!

This is my first time creating the 3-axis movements (plus jaw) from scratch, typically someone else beats me to it so I decided to combine my 3D printing ability, my limited mechanical knowhow and give this a whirl. I'm quite happy with the results!

I'm pretty sure this will void the warranty on your Skelly! LOL

Many of you have asked, so for those that feel brave enough to cut open their Skully, I've decided to start offering the 3D Printed Parts for sale. They will be listed on my Etsy page here: https://skellyparts.com

Details

This project covers the construction of the mechanical parts and installation into the skull. It does NOT cover the electronics or programming of the routines.

I do not recommend doing this project if you are not comfortable with servos or animatronics. I'd recommend starting with a smaller 'normal size' skull first. Like those available from HalloweenSkulls.com or Skulltronix.com

WARNING: You will be cutting large holes in your plastic skull as well as separating the jaw from the skull. You will also need to cut the metal pipe that protrudes out of the neck a small amount so it doesn't interfere. Be careful and make sure you are comfortable with this!!!

NOTE: This is not meant to be water-resistant!!! If you plan to keep you Skully out for the month of October, this may not be meant for you... or try to find a 2nd head you can swap in!

DUE THIS AT YOUR OWN RISK!!! I AM NOT RESPONSIBLE FOR ANY INJURIES OR DAMAGE YOU MAY CAUSE.

Components

1 × 3D Printed Parts (see external link to Thingiverse) For printing the parts of course!

3 × Hitec HS-805BB w/ included Servo Arm and Hardware Hitec Giant Servos for Yaw, Roll & Pitch

1 × Hitec HS-425BB w/ Servo Arm For the Jaw movement

1 × Thrust Needle Roller Bearings with Washers 20mm Bore, 35mm OD

1 × Flat Steel Bar (cut into 2 pieces) 1/8" thick, 1/2" wide

Project Logs

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3D Printed Parts available now
Nelson Bairos • 01/30/2023 at 23:55 • 0 comments

Many of you have asked, so for those that feel brave enough to cut open their Skully, I've decided to start offering the 3D Printed Parts for sale.
They will be listed on my Etsy page here: https://skellyparts.com
3D Printed Parts available now
Nelson Bairos • 01/30/2023 at 23:54 • 0 comments

Many of you have asked, so for those that feel brave enough to cut open their Skully, I've decided to start offering the 3D Printed Parts for sale.
They will be listed on my Etsy page here: https://skellyparts.com
2022 Update: Improved Printability
Nelson Bairos • 07/05/2022 at 00:10 • 0 comments

UPDATE 7/4/2022: Split the 2nd Level into 2 pieces that are screwed together with 4x M3x20 screw AND added a channel in part B for the wires of the servo to pass easily. This makes printing the part easier (no mega supports).
Public Debut!!!
Nelson Bairos • 10/26/2021 at 12:20 • 0 comments

Tiny (that’s his name) made his public debut! Everyone loved him. 3 straight nights of talking without a hitch.

View all 4 project logs

Build Instructions

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Interface assemble

Start with the (white) 3D printed part called "Skull_Mech_V3_Interface" This connects to the neck of the skeleton.

Make sure the shaft is smooth, sand it down a little if needed.
Slide the thrust needle bearing assembly down (washer, bearing, washer)
Screw in the two M3 screws (thread length around 12mm) at the top of the part. These will tighten the rotation servo onto this part later. Don't tighten the screws.

Rotation Servo installation

You will be using the 1st level (blue) 3D part labeled "Skull_Mech_V3_1stLvl"

Remove the servo arm (and screw) from the servo.
Position the Rotation servo as shown and attach with the included hardware.
1. There are holes in the 3D model for aligning the servo screws.

Tilt Servo Installation

Still using the 1st level (blue) 3D printed part.

Install the servo arm shown (you may need to remove and adjust its position later on).
Position the Tilt servo as shown and attach with the included hardware.

Discussions

Montanadude wrote 3 days ago

Am I confused or are the eyes in your video using graphics or oled's? If so, do you have details for the setup and such for them? Also, where exactly did you get the head as on thingiverse I only see the rest of the parts to print? Thanks a bunch.

Are you sure? yes | no

martinisaacanywhere wrote 01/20/2023 at 20:19

I’d like to try this, but can’t find the links or files… am I missing something?

Are you sure? yes | no

Nelson Bairos wrote 01/31/2023 at 00:46

Hi, the link to the files is in the links section. Here it is again: https://www.thingiverse.com/thing:4926224

Are you sure? yes | no

martinisaacanywhere wrote 01/31/2023 at 03:27

thanks! I can’t wait to try this. How did your progress come along for the coding? Thanks ve had some success using chatterpi in the past, and now that some raspberry pis are back in stock, so I think I’m going to give that a shot for this project. Thanks again.

Are you sure? yes | no

Nelson Bairos wrote 01/31/2023 at 13:59

@martinisaacanywhere Just an FYI that I'm working on improving the engagement between the rotation servo and plastic. As another comment below mentioned, it can be a week point. So I'd hold off printing the rotation part (white piece). As far as programming, I use a stick PC with Brookshire Software's VSA and my LifeApe software. I've been tinkering with PI but nothing ready yet.

Are you sure? yes | no

redpawFX wrote 11/02/2022 at 20:32

I printed this up for this halloween and it worked really well. Thanks so much for the design! I did upgrade the servos to heavier duty metal gear ones and used a 1/4 scale servo for the jaw as well. The only part I think could possibly use a little tweak would be the head turn servo interface. I may have a hack at trying to physically bolt on a servo horn to the top of the "stem" so it has proper splines to mesh with, or reworking the model a bit so it prints with room for embedded nuts for the tightening screws to thread into.. I melted in my own for now, but if it thrashes on a reset of the programming it could still slip and rotate further around, as happened to me at first before I tightened it down.

Are you sure? yes | no

Nelson Bairos wrote 01/31/2023 at 14:01

@redpawFX Sorry for the super late response. Glad it went well. As far as the rotation servo goes, I've had the same issues and am working on an update to better address the issue. Stay tuned, I'll post an update here and on Thingiverse.

Are you sure? yes | no

sbbbugsy wrote 12/24/2021 at 04:06

Any chance that you will make this a kit?

Are you sure? yes | no

3-Axis Skull Mod for 12ft Skeleton

Description

Details

Components

Project Logs

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3D Printed Parts available now

3D Printed Parts available now

2022 Update: Improved Printability

Public Debut!!!

Build Instructions

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Discussions

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3-Axis Skull Mod for 12ft Skeleton

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