Ms D. Campos - Outdoor Tombstone Popper

I wanted to make a Halloween decoration for the front of my home. I wanted something different and something that would move. It also has to be weatherproof. I did some searches on the web and found something called a "Tombstone Popper". I have never done any animatronics but after watching a few videos decided to try it out:

Here is a list of the supplies I used:

1. Aluminum Flat Bar: https://www.homedepot.com/p/Everbilt-1-2-in-x-36-in-Aluminum-Flat-Bar-with-1-16-in-Thick-800217/204604762
2. 3/4 24x24 Plywood: https://www.homedepot.com/p/Columbia-Forest-Products-3-4-in-x-2-ft-x-2-ft-PureBond-Red-Oak-Plywood-Project-Panel-Free-Custom-Cut-Available-2854/204771251
3. Flat Black spray paint and misc nuts and screws
4. Waterproof ABS Plastic Project Box: https://www.amazon.com/dp/B0BGMX73TB
5. Creepy Mask: https://www.amazon.com/dp/B0CXDW5VHW
6. Power supply for motor: https://www.amazon.com/dp/B01GEA8PQA
7. Motor Hub: https://www.amazon.com/dp/B0D1RJ9BZP
8. Turntable Motor: https://www.amazon.com/dp/B088Q7372R
9. Foam Head: https://www.amazon.com/Model-Mannequin-Display-Manikin-White/dp/B0CKH6BFVH

Step 1: Prepare the Project Box

1. Mark the Location for the Motor Shaft: Identify where you want the motor shaft to stick out of the project box. Use a pencil or marker to mark the spot.
2. Drill a Hole for the Motor Shaft: Using a drill, create a hole in the project box large enough to allow the motor shaft to protrude through.

Step 2: Attach the Motor to the Project Box

1. Align the Motor with the Shaft Hole: Position the motor inside the project box so the shaft extends through the hole you drilled.
2. Secure the Motor with Screws: Use two screws to attach the motor to the inside of the project box. Ensure the motor is firmly in place and aligned properly.

Step 3: Create a Hole for the Power Supply

1. Mark the Location for the Power Supply Cable: Determine where the power supply will enter the project box. Mark the location on the side of the box.
2. Drill a Hole for the Power Cable: Use your drill to create a hole just large enough to allow the power supply cable to pass through.
3. Attach the Power Supply to the Motor: Feed the power supply cable through the hole and connect it to the motor's power terminals according to the motor’s wiring specifications.

Step 4: Attach the Aluminum Bar to the Motor Hub

1. Cut the Aluminum Bar: If you haven't already, cut a piece of aluminum bar to about 3 inches in length.
2. Attach the Aluminum Bar to the Motor Hub: Using screws or the appropriate fastener, attach one end of the aluminum bar to the motor hub.
3. Add a Screw at the End of the Bar: Insert a screw at the free end of the aluminum bar. This will act as an attachment point or stopper for the next component of your project.

Step 5: Attach the Project Box to the Plywood

1. Position the Project Box on the Plywood: Place the project box on the plywood in your desired position.
2. Secure the Project Box to the Plywood: Use screws to firmly attach the project box to the plywood, ensuring it's stable and secure.

Step 1: Prepare the PVC Pipe

1. Cut the PVC Pipe (if needed): Ensure your PVC pipe is 2 feet long and 1/2" in diameter. If it's not already the right size, cut it to the appropriate length.

Step 2: Attach the PVC Pipe to the Foam Head

1. Position the Foam Head: Take the foam head and locate the base (neck area) where you will attach the PVC pipe.
2. Attach the PVC Pipe: Secure the PVC pipe to the base of the foam head. You can either insert the pipe slightly into the foam or glue the end of the PVC pipe to the base of the foam head using a strong adhesive or a hot glue gun.
3. Allow the Glue to Dry: Hold the pipe in place until the glue sets, and ensure it is securely attached before proceeding.

Step 3: Glue the Mask to the Foam Head

1. Prepare the Mask: Position the mask on the foam head where you'd like it to be glued.
2. Apply Glue to the Mask: Apply glue around the edges or the attachment points of the mask and press it onto the foam head.
3. Hold the Mask in Place: Hold the mask in place for a few minutes to ensure the adhesive bonds correctly. Allow sufficient drying time according to the glue instructions.

Step 4: Drill a Hole at the Bottom of the PVC Pipe

1. Mark the Hole Location: At the bottom of the PVC pipe, mark where you want to drill a hole.
2. Drill the Hole: Using a drill, carefully create a hole through the bottom of the PVC pipe. This hole can be used for securing the pipe or for attaching additional components to your setup.

Step 1: Cut the Aluminum Bar

1. Cut the Aluminum Bar to Length: If it's not already done, cut a piece of aluminum bar to 1 foot (12 inches) in length.

Step 2: Curve the Aluminum Bar

1. Measure and Mark the Curve Point: Measure 6 inches from one end of the aluminum bar and mark it. This will be the midpoint where you’ll create the curve.
2. Bend the Bar: Using pliers, a vice, or a bending tool, carefully curve the aluminum bar at the 6-inch mark. You can make a gentle or sharper curve, depending on the needs of your project. Ensure the curve is stable and aligned correctly for attachment.

Step 3: Add Foam Padding to the Aluminum Bar

1. Apply Foam Padding: Cut pieces of foam padding to fit along the curved section of the aluminum bar. This padding will help to reduce movement and provide cushioning.
2. Attach the Foam Padding: Glue or tape the foam padding securely to the curved portion of the aluminum bar. Make sure the foam is tightly secured so it won’t move during operation.

Step 4: Drill a Hole in the Aluminum Bar

1. Mark the Hole Location: Determine where you need to attach the aluminum bar to the motor arm. Mark this location on the bar.
2. Drill the Hole: Use a drill to create a hole through the aluminum bar where you plan to attach it to the motor arm.

Step 5: Attach the Aluminum Bar to the Motor Arm

1. Align the Hole with the Motor Arm: Position the aluminum bar so that the hole you drilled lines up with the motor arm.
2. Secure with a Screw: Insert a screw through the hole in the aluminum bar and into the motor arm. Tighten it securely so that the aluminum bar is firmly attached to the motor arm.

This is without panting