Knee Spike Kit Fabrication

Seal cast and cut out holes that allign with the knee axis.

Lubricate allignment mandrell and position as knee axis. Seal the mandrell to the cast.

Prepare negative cast for plaster pour.

Pour plaster mix..

Remove plaster from areas above the medial condyle for suspension.

After the plaster mix has hardened, remove the original casting.

Add just enough plaster to the medial calf to eliminate the convexity of the calf. Run your mold buildup at the same angle as the knee joint head.

Set the knee joint alignment tool in place, with the aluminum head butted to the mold.

Add plaster as needed in accordance with the level of bony prominence of the fibular head .

Add plaster as needed to seal in the allignment tool to your mold. Make sure there is a noticible ledge on the proximal and distal sdges of the allignment tool. This will allow resin to saturate the fibers and leave the joint heads free from fibers.

Seal plaster cast with laquer or equivelant

When the laquer has dried and is no longer tacky, apply a layer of pantyhose to reduce friction on the coming layer of PVA..

Pull a PVA bag over your mold and burn a hole in each of the screw holes beneith your PVA.

Afix your Knee Spike uprights to the mold. Make sure there is clearence between the spikes and your mold so there is enough room for the fibers and resin.

Cut and apply the Ultra-G braid on the claf section, and hold it down with pantyhose or stockinette.

Apply tape or foam over the screw heads to make removal easyer after laminating. Cut and apply the Ultra-G braid on the theigh section, and hold it down with pantyhose or stockinette.

Add cosmetic finishes such as stockinet and or printed patterns. Pull PVA bagging down over full mold and seal to your vacume source. Establesh a resevoir for the introduction of liquid resin. Dehydrate the bag for strength during the lamination.

Introduce your resin and work it into the Ultra-G fibers under vacume. Our lab uses true acrylic resin that requires desication prior to pour. Use proper safety equipment and ventilation during this and all lab process.

Remove composite shells from your mold. * Use proper safety equipment and ventilation during this and all lab process.

Grind excess resin from your shells. * Use proper safety equipment and ventilation during this and all lab process.

Assemble Knee Spike joint head.

Attach straps and chafes.

Clean inside surface of joint and cement cyndyle pads onto them

Apply the Strap-EZ pads as desired. The knee brace is ready for fitting!