Take your 6 1/2'' piece and place it in the vise with the 1 1/4'' line at the top of the jaw, this is your bend line. Take soft hammer and hit the aluminum close to the vice to bend it. Don't hit high, this will screw the piece up. Keep hitting till you have a 90 degree. Repeat for both ends.
Below is picture of Left front leg for boney ready to be assembled. Remember to position the leg on body and servo mount faces forward and notch for mount goes in leg half with no holes.
I added a material list to save a lot of trips to the hardware store. You will need to get the 4qty 10-24x 2 1/2'' Stainless Machine screws and file the threads a little to slide the FR-166-ZZ Bearings over the screw. I was able to slip the head of the bolt up inside the drill press chuck. I turned drill on and made sure it was running straight and lightly filed the threads. Stop the drill and check the bearing fit. Then flip the screw and file the remaining threads. Check bearing fit, do not force bearing on.
When you disassembled the legs there were nylon spacer that the bolts went through. They need to be cut and drilled. Place spacer in vice and cut top off and small collar on opposite end . Drill out to 3/16''. Reference the pictures below.
Started assembly of Boney #2 to get him close to Boney #1. I will add pictures as I go, pictures are better than words. Drilling out shoulders and hips for bearing installation. It is very important that you start out with a small drill bit and work your way up and finish with a 3/8 bit. The bearing I used was a FR-166-ZZ and you will need eight, one for inside and one outside of hips and shoulders. Use one to check fit but do not install them yet. The nylon inserts will pop out. I left them in to drill, to help hold them.
Next, dissemble the four legs and save the small screws, you can pitch the machine screws, nuts and springs. Mark the inside of the legs LF -Left Front , LR- Left Rear RF-Right Front , RR-Right Rear you will be cutting the legs at the knee, so mark each piece at both sides of knee. Marking the legs for cutting at the knee I used a pencil to mark them and you can refer to the picture above as reference.
I purchased 2 skeleton dogs from Home Depot. After Halloween I was able to get one 50% off for $12.50. I am building two, you will only need one, you can try to go on Depots' site and see if you can still get one. I purchased 1/8'' x 1 1/2'' x 8' aluminum flat stock at Lowes and used just under 5' to fabricate one set of brackets. I used all stainless fasteners to assemble the dog, which I purchased at Lowes and on eBay I got the 4-40 nylon locks and 4-40 machine screws. The 6-32 machine screws and 10-24 machine screws I got at Lowes. I will work on fastener list and other supplies needed. Also a tool list, one very important tool is metal cutting band saw and drill press. If you don't have these tools the project will not be fun to build and its about having fun. Let me know if you are interested in building this project so I can give you as much detail as possible.