Foam to Wood Mannequin

In response to all wishing to replace a Full Moon replica’s original foam body with a wood mannequin body I devised what I believe would be the simplest way.

Before starting, please understand that there is a certain amount of risk involved with altering your replica from its original form, in other words, I would not want to see anyone attempt to change their replica, and not be able to finish the project, or end up with a headless replica, etc.

The wood mannequin bodies use a series of internal springs to not only allow articulated movement but also keep the pieces together. Once a spring is un-hooked from any part the mannequin will fall apart. Therefore each spring must be attached at both ends.

NOTE: The springs are under high tension and can cause serious injury to your hands and fingers.

Notice in this photo, the outer diameter of this mannequin’s head was reduced to allow attachment of the replica head. This step is rather time consuming but can be eliminated by vertically drilling a medium size hole into the replica’s head, along with a horizontally drilled very small hole about about the size of a nail, which a nail is inserted to retain the spring.

In other words, picture the replica’s head being the original mannequins wooden head, but with a 3/8 – 1/2 inch hole drilled into it.

Tools and Materials required:

  • Drill.
  • Drill Bit either 3/8 or 1/2 inch.
  • Drill Bit either 1/32 or 1/16 inch.
  • Finishing Nail either 1/32 or 1/16 inch.
  • Pair of needle nose pliers (to retain spring)

This technique will not allow for a very stable head, but will work, and can be done in a very short time compared to the method used on my other replicas. However a more stable head can be achieved by eliminating the pivot ball all together, which means the boar and placement of the nail needs to be deeper into the head cavity.

If all goes well, you will have the mannequins original wooden head, hands, and maybe even the pivot ball left over.

This same technique can also be used to mount the replica’s original plastic weapons to the body.

I hope this makes sense, as I have not actually used this method to attach a head. Please feel free to contact me if you have any questions regarding this post.