Internal detachable structure

In order for the torso to slot on and off the legs (like the arms from the torso). I needed to construct two parts - one that will be imbedded in the legs sticking up and another that is secured into the fibreglass core of the torso. I'll put both parts together during the foaming of the legs so it'll always slot on in the position it was sculpted in.

These slotting supports need to be super strong because of the weight of the head and torso - I used steel box section and steel bar - I steel bar was slightly too large to fit inside the box section so I had to mill down two sides so it fitted snug.

Both steel sections were welded to some steel plating. I drilled holes in the plating so the bridger and fibreglass could secure the plate that went inside the core better and so the PU foam would expand round the holes and lock the other plate in place.

The last picture shows the support that will eventually sit inside the legs. Now this is done I can now start foaming the arms and legs...

Fixing arm slots into the core

So just like the torso and legs - the arms will slot on and off the torso for ease of transportation. Before I foamed the arms I milled down two sections of smaller steel bar to fit in some different sized box section - shown in the photos below - I suspended the steel bar sections in the arms when foaming and the box section will be glassed into the torso core. Hopefully the photos will explain properly!

After temporarily fixing the box section in with bridger (Isopon P40) and letting it fully cure, I carefully unslotted the arms and reinforced the bridger with standard fibreglass matting and resin.