I've made custom shoulder joints for the knight I'm currently building.
The trickiest part is finding a tube of the proper size to fit the socket. I found that 3/4" PVC pipe had the right inside diameter, but it's OD was too large. If you have access to a lathe this is easy to fix. I ended up using a makeshift setup involving a power drill, vice and a chisel to get my pieces turned down to the right size. You could probably make your own tube out of very thin plasticard wrapped a few times around a dowel and then glued fast. Final result, you want a tube with an OD 15/16" or less and an ID a smidgen larger than 3/4".
For the next step, I took some thick plasticard (I had.060, .080 would probably worked better) and cut off a thin strip, basically making a square rod. This will form the retention rim inside the tube. Cut a piece that will bend in a circle and fit snug inside the tube. Glue it in place on one end of the tube. Now cut out a notch where the ends of the rod met, and another directly opposite. This should now fit into the shoulder socket just like the original.
I then cut out a 3/4"plasticard disk to use as a base for the rest of my shoulder joint assembly, which was then slid in place and glued into the tube. It shouldn't be hard to replicate the original from here.
|