This was perhaps the biggest challenge yet on this project. Since none of us really have any experience building prosthetics, it was an incredible learning experience. It involved building the cast with plaster, connecting a 5' PVC tube to it and then mixing/cooking the gelatin, pouring it to create the cast.
This is what the gelatin appliance looks like.
And here is an interesting arrangement we used to pour the gelatin and erect the cast. With nothing more than random found objects in my apartment. Epic indeed t'was!
What you see there is a Styrofoam head with a tube drilled into. Dunked into a plaster cast in the blue bucket. Fitted into another PVC tube. Standing upright using a crutch!