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  #1  
Old 08-26-2008
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Default HeadPopper How-To

I have made a modified version of the BairdManor Headpopper prop. This prop was the group project at the IN/KY Make N Take for August, 2008.

Thanks to BairdManor for the inspiration.
http://www.my-mania.com/halloween/headpopper.html

My version utilizes the same mechanism, but has a much smaller (and less expensive) motor. This version is designed to use a styrofaom head or skull since the motor will not lift as much weight as the wiper motor used by BairdManor. This mech will work with a 30 in tall tombstone, but can be easily modified to fit other size stones.

Materials: ( all purchased at Menards other than the motor/wallwart)
16" square of 1/2 inch plywood, cut in half (two 8" X 16" pieces)
20"long 1" X 4" wood slat
1/8 X 1/2" aluminum bar stock, cut into 5" and 25" lengths
3/8" X 4-1/2 inch lag Screw Eye
two 1/4-20 X 1.5" Bolts
three 1/4-20 Nuts
two 1/4" lock washers
one 1/4-20 locking nut
two 1 1/2" wood screws
Motor http://www.surpluscenter.com/item.as...-1587&catname=
12Vdc wallwart



Start by assembling the platform as pictured. Screw the wood slat in the center of one of the plywood pieces and then screw the two plywood pieces together to form an 'L'. Drill a 1/4 inch hole sixteen inches from the bottom of the wood slat, and install the Lag Screw Eye.


Drill a 1/4 inch hole in each end of the small aluminum bar. This will become the crank arm. Install the 1-1/2 inch bolts, nuts, and lock washers as shown.


Thread the bolt shown into the motor shaft. It may be necessary to use a 1/4-20 tap to make threads inside the motor shaft.


Screw the assembled motor/ crank arm to the 4"wide wood slat. Make sure to align the motor shaft with the center of the slat, and that the crank arm has approx. 1/2 inch clearance at the platform base.
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Last edited by dave the dead; 08-26-2008 at 07:43 PM.
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Old 08-26-2008
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Next, install the 25" long piece of aluminum stock thru the lag eye screw and onto the crank arm bolt. Loosely secure it with a locking nut, leaving space for the long bar to rotate freely on the crank arm.



Secure the foam head or skull to the top of the aluminum bar.Secure the tombstone to the front of the platform, making sure the foam head or skull does not hit the stone while the motor is rotating.(add in a spacer board between the platform and the tombstone if necessary.


behind the scenes video
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Last edited by dave the dead; 08-26-2008 at 09:04 PM.
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Old 08-26-2008
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Thanks Dave. I GUESS this is as good as being there in person for the make and take *kicks heel into the dirt*...I guess.

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Old 08-26-2008
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thanks Dave - bookmarked it for next year.
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Old 08-26-2008
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I got mom in law to try this as her first "fancy" prop. Thanks for the great tutorial Dave!
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Old 08-26-2008
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http://http://www.youtube.com/watch?v=4CgWRUz15TQ
Ok here is the prop.
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Old 08-26-2008
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thanks Dave...looks easy
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Old 08-27-2008
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Great looking prop, Dave!

The only concern I have is that when I looked on the Surplus Center link, it listed the motor as "intermittant duty".

I made the mistake of buying an intermittant duty motor (actually, two of them) from them a few years ago, not realizing it until I had them in my posession. They refused to take them back, since they are an electrical item, and I was stuck with two half-horse motors that would kick out on thermal overload after running for a minute or two. Hope you don't have the same problem.

Ron
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Old 08-27-2008
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Quote:
Originally Posted by Runfromron View Post
Great looking prop, Dave!

The only concern I have is that when I looked on the Surplus Center link, it listed the motor as "intermittant duty".

I made the mistake of buying an intermittant duty motor (actually, two of them) from them a few years ago, not realizing it until I had them in my posession. They refused to take them back, since they are an electrical item, and I was stuck with two half-horse motors that would kick out on thermal overload after running for a minute or two. Hope you don't have the same problem.

Ron
Not to worry about the "intermittent duty"...I have several of these motors in use this year, and have tested them for 6 to 8 hours at a time with absolutely no problem.
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Last edited by dave the dead; 08-27-2008 at 10:14 AM.
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Old 08-27-2008
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Thanks for the howto Dave. I'm putting this on my must have list.
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