PVC Pipe:
We will typically build the entire frame with 3/4" PVC pipes. They are lightweight, not too bulky, and can hold quite a bit of weight. Occasionally, we will use 1/2" PVC pipe, but not for the main frame, usually for decorative pieces. This can be found at any home improvement store such as Lowe's, Home Depot, or Menards. However, be careful not to get the thin walled PVC as it will shatter with too much weight. Be sure and get the thicker, more sturdy PVC.  

PVC Joints:
There are a variety of joints we use for building wheelchair costumes with PVC. The most common are 90's, 45's, and T's. We have also found some others quite useful as well, even though they are sometimes a little harder to find and sometimes have to be ordered online. Those consist of Pluses, Corners,  4-Way Corners, Saddle Joints, and a Slip Joint Union. ​These can be found at any home improvement store such as Lowe's, Home Depot, or Menards.

Also, don't forget to check out our custom designed 3D printed joints we created on our 3D Joints page. 

Styrene:
A product we have found to be very useful in skinning the costumes is a product called Styrene. It's basically PVC sheets. We use 060 Styrene in 3 mm thickness. You can buy a 4' x 8' sheet for roughly $35.00. Check local sign making companies to see if they carry it. Styrene can be cut with a box knife, but you might have to score it 2-3 times before you fold it and it will snap right on your cut lines. It can be painted with spray paint and dries quickly. Vinyl stickers also work wonderfully on it. 

SKS Props HD-Foam:
​SKS Props HD-Foam is a sturdy EVA (Ethylene-vinyl Acetate) material that is easy to cut with scissors and utility knives. After it has been cut to size, HD-Foam can be shaped easily with heat. Because of its lightweight nature, HD-Foam is often used for making helmets, armor, and more organic shapes such as animals. We have also used it on fighter jets and Star Wars vehicles too. It works equally well with CA glue, super glue, hot glue, and contact cement adhesives. It also accepts a variety of paints and primers. It comes in rolls, as well as different shaped dowels which are great for adding details and more. The dowels come in round, half-round, and triangle, and each of those come in 3 different sizes. 

SKS Props Lightweight Foam Clay can be pressed into molds or sculpted by hand. It also works well for filling seams. Water can be added to smooth it. When dry, Foam Clay cures into a dense material resembling EVA foam, and can be cut, sanded, glued, primed, and painted. It's acid-free and works well with CA glue, super glue, hot glue, and contact cement adhesives.

Glues and Adhesives:
When working with new materials, it's often confusing to know what types of glues and adhesives to use. While you can use hot glue, super glue and rubber cement for minor details, the big job of the frame and HD-Foam require something different. 

Oatey Fusion Single Step - This is what you want to use for glueing the PVC pipes together. Put it in the joint, push the pipe into the joint, and you have about 30 seconds before it is a solid bond. Make sure to mark the angle of all joints before glueing or you might find yourself rebuilding some of the frame. (Note: the frame will shrink slightly)

Contact Cement or Barge Glue - This is used to adhere HD-Foam together. For those who have never used this before, you apply it to both sides you are sticking together, but DO NOT put them together while the glue is wet. Wait until both sides are completely dry, then when you stick them together, be very careful because once they touch, they will NOT come apart. It will tear the HD-Foam before the glue joint comes apart.