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| How To Make A Peg Leg... For Dummies. |
Jim lost part of his right leg below his knee
when a storm struck & sunk his
ship to the bottom of the sea.
A truck collided with his motorcycle the night of June 6th
2000 but he sailed on through life like a real survivor,
along with some new creative ideas. He envisioned a peg
legged pirate. One who performs magic and speaks
words of wisdom. He thought that this seemed like a very
interesting and entertaining character. At 35 years old
he pursued this by gathering pirate garb and picking up
the magic that he once performed in childhood. He
began to practice and perfect his look and illusions. He
took his first prosthetic leg and would remove the foot
and install a metal pylon with a rubber stopper to create
the look of a peg leg. He would perform for friends and
reinstall the foot when he was not performing. After
having the wrecked bike put back together again he had
it painted a silver & black theme with his prosthetic leg to
match. This was a first for the custom bike painter. Jim
renamed his Harley Davidson Night Train Softail the
"Second Chance Night Train." Jim would get some
double takes as he road his Harley with matching leg,
sporting the peg leg look at times as well.
when a storm struck & sunk his
ship to the bottom of the sea.
A truck collided with his motorcycle the night of June 6th
2000 but he sailed on through life like a real survivor,
along with some new creative ideas. He envisioned a peg
legged pirate. One who performs magic and speaks
words of wisdom. He thought that this seemed like a very
interesting and entertaining character. At 35 years old
he pursued this by gathering pirate garb and picking up
the magic that he once performed in childhood. He
began to practice and perfect his look and illusions. He
took his first prosthetic leg and would remove the foot
and install a metal pylon with a rubber stopper to create
the look of a peg leg. He would perform for friends and
reinstall the foot when he was not performing. After
having the wrecked bike put back together again he had
it painted a silver & black theme with his prosthetic leg to
match. This was a first for the custom bike painter. Jim
renamed his Harley Davidson Night Train Softail the
"Second Chance Night Train." Jim would get some
double takes as he road his Harley with matching leg,
sporting the peg leg look at times as well.
The word of this peg legged
magical pirate was spreading.
A new local seafood restaurant in Greensboro
called on him in October of 2004 and hired him
to entertain several nights of the week. This
was his big break to be seen more by the
public. He soon started having a new
prosthetic leg made. One that would be strictly
used as his peg leg. He then could leave the
foot on his first leg. He had the upper part of
the prosthetic leg the "socket" painted to look
like wood grain. The socket is made of carbon
fiber and fiber glass. Very strong materials that
are used in making artificial limbs (prosthetics.)
The lower part, the "peg" was a metal pylon
with a rubber stopper. Now known as Captain
Jim, he wore this leg for the next several years,
performing at all types of parties and events.
magical pirate was spreading.
A new local seafood restaurant in Greensboro
called on him in October of 2004 and hired him
to entertain several nights of the week. This
was his big break to be seen more by the
public. He soon started having a new
prosthetic leg made. One that would be strictly
used as his peg leg. He then could leave the
foot on his first leg. He had the upper part of
the prosthetic leg the "socket" painted to look
like wood grain. The socket is made of carbon
fiber and fiber glass. Very strong materials that
are used in making artificial limbs (prosthetics.)
The lower part, the "peg" was a metal pylon
with a rubber stopper. Now known as Captain
Jim, he wore this leg for the next several years,
performing at all types of parties and events.
Newspapers & TV were interviewing this Pirate
and telling this lemons to lemonade story.
Captain Jim was now performing at a couple of different restaurants each week.
Weekends were filling with birthday parties, church events, festivals...etc. Jim was
excited and so thankful for the success of this character that he had created. He's
always working on bigger and better illusions and more powerful words of wisdom,
fine tunning his pirate look and show. But there was one thing that he knew he
needed to make his look more authentic. Although the peg leg he had was a definite
eye catcher he still got the occasional "that's not a real wooden leg" from some
children. He new he needed a real wooden peg leg. He went to his Prosthesis (a
person who makes artificial limbs) with this new idea. They were use to his creative
ideas and were excited to be apart of the creation of a real wooden peg leg. Jim had
an idea of having a new prosthetic socket made to fit his limb with no hardware
below the socket. No metal pylon no place to install a foot just the carbon fiber
socket. Jim then went to a local custom mill shop. One that he had dealt with in his
construction days. He a craftsman who was intrigue with this unquiet project. Several
months of planning went on. Jim's Prosthesis made him a new socket even covered
it in a wood grain fabric just in case the real wooden cover did not work out. It looked
awesome already. Mean time the wood craftsman had drawn blueprints of his ideas.
He would make an upper wooden shell with the lower part being solid wood. He then
would shape this piece of wood into the look of a peg leg and mount the carbon fiber
prosthetic socket in the upper shell. This way you would have it fit the limb with
todays technology for comfort but the look of a real wooden peg leg.
and telling this lemons to lemonade story.
Captain Jim was now performing at a couple of different restaurants each week.
Weekends were filling with birthday parties, church events, festivals...etc. Jim was
excited and so thankful for the success of this character that he had created. He's
always working on bigger and better illusions and more powerful words of wisdom,
fine tunning his pirate look and show. But there was one thing that he knew he
needed to make his look more authentic. Although the peg leg he had was a definite
eye catcher he still got the occasional "that's not a real wooden leg" from some
children. He new he needed a real wooden peg leg. He went to his Prosthesis (a
person who makes artificial limbs) with this new idea. They were use to his creative
ideas and were excited to be apart of the creation of a real wooden peg leg. Jim had
an idea of having a new prosthetic socket made to fit his limb with no hardware
below the socket. No metal pylon no place to install a foot just the carbon fiber
socket. Jim then went to a local custom mill shop. One that he had dealt with in his
construction days. He a craftsman who was intrigue with this unquiet project. Several
months of planning went on. Jim's Prosthesis made him a new socket even covered
it in a wood grain fabric just in case the real wooden cover did not work out. It looked
awesome already. Mean time the wood craftsman had drawn blueprints of his ideas.
He would make an upper wooden shell with the lower part being solid wood. He then
would shape this piece of wood into the look of a peg leg and mount the carbon fiber
prosthetic socket in the upper shell. This way you would have it fit the limb with
todays technology for comfort but the look of a real wooden peg leg.
LEFT: Captain Jim
Prostheses, Jeffrey Smith
of Advance Prosthetic &
Orthodics in Greensboro,
N.C. Jeff tweaking Jim's
new leg which has pirate
skull fabric embedded
into the carbon fiber. Jim
is holding his new socket
that will be used with his
wooden peg leg.
RIGHT: The carbon fiber
socket covered in wood
grain fabric. If a peg had
been added and covered
in this fabric this alone
would have been
awesome. Needless to
say Jim was as excited as
a kid in a candy shop.
Prostheses, Jeffrey Smith
of Advance Prosthetic &
Orthodics in Greensboro,
N.C. Jeff tweaking Jim's
new leg which has pirate
skull fabric embedded
into the carbon fiber. Jim
is holding his new socket
that will be used with his
wooden peg leg.
RIGHT: The carbon fiber
socket covered in wood
grain fabric. If a peg had
been added and covered
in this fabric this alone
would have been
awesome. Needless to
say Jim was as excited as
a kid in a candy shop.
Precision work and calculations have to go into both the carbon fiber prosthetic and the wooden peg leg.
Both craftsmen are the best in their fields. Captain Jim will ware the peg leg for long lengths of time. The prosthetic
socket has to fit his limb precisely so to not wear or rub and cause him undue skin break down or pain in his leg or hips.
The wooden peg leg has to be exactly the right size. The hole in the shell just right to receive the carbon fiber
prosthetic. Making it no bigger than it has to be and the length just right. Once completed there will be no way to adjust
the height on the wooden peg leg like there is on a standard prosthetic leg. The goal is for it not to be any bulker than it
has to be and definitely not to short. It started as 29 inches heigh and about 50 lbs. A lot had to be whittled away.
Both craftsmen are the best in their fields. Captain Jim will ware the peg leg for long lengths of time. The prosthetic
socket has to fit his limb precisely so to not wear or rub and cause him undue skin break down or pain in his leg or hips.
The wooden peg leg has to be exactly the right size. The hole in the shell just right to receive the carbon fiber
prosthetic. Making it no bigger than it has to be and the length just right. Once completed there will be no way to adjust
the height on the wooden peg leg like there is on a standard prosthetic leg. The goal is for it not to be any bulker than it
has to be and definitely not to short. It started as 29 inches heigh and about 50 lbs. A lot had to be whittled away.
BELOW: Custom Furniture Designer/Maker, Christopher Hanlon of Hanlon Designs in High
Point, NC. Turns the block of wood on a layth over a period of 4 hours. Using only a hand
tool called a ------ to shape it into the look of a peg leg. Detail is of the up most importance.
There is no room for mistakes. As a added compliment but necessary to the leg, brass pegs
are installed to help fasten the lower solid peg to the upper hollow shell. You would have
never known watching Christopher that this was his first time making a peg leg.
Point, NC. Turns the block of wood on a layth over a period of 4 hours. Using only a hand
tool called a ------ to shape it into the look of a peg leg. Detail is of the up most importance.
There is no room for mistakes. As a added compliment but necessary to the leg, brass pegs
are installed to help fasten the lower solid peg to the upper hollow shell. You would have
never known watching Christopher that this was his first time making a peg leg.
The finished product is a well fitting work of art that these craftsmen
can proudly stand behind and Captain Jim can proudly stand on.
Over a few more days Christopher would sand and sand the peg leg. Giving it an
extremely smooth finish then applying several coats of sealer. Chris installed the
carbon fiber prosthetic into the shell bonding it with a harding foam. Once this had set
up he contoured the top of he wooden peg leg to meet the contours of the carbon
fiber prosthetic. Both Jeffrey and Christopher had to be precise with these contours in
order for Captain Jim to be able to bend his leg without having any discomfort. The
hours of meticulous shaping of the peg leg had taken the height down to 22 inches
and the weight to 20 lbs. No more could be taken off the diameter of the wooden leg.
The walls of the wooded upper half had to stay thick enough so not to come apart
over time. Captain Jim came for the finish product. It was beautiful and just what he
envisioned. It was definitely more meatier looking than the old style peg leg but that's
what he wanted. Captain Jim wanted this leg to make a statement and a grand
statement this Brazilian Cherry peg leg did make. The one last concern was the
weight of this wooden peg leg. Captain Jim's other carbon fiber prosthetic legs and
peg legs weigh about 10 lbs and from the get go Chris and Jim realized that this leg
would be much heaver. A lot of time and financial investment went into this wooden
peg leg. The big question now was how long could Jim ware the leg before
it caused him discomfort due to the weight. Captain Jim slid the limb or his right leg
into this gorgeous wooden peg leg for the first time. As he walked around the shop he
became more excited with every step. Yes much heaver than his other legs but a
great fit none the less and one thing was for sure, it's a real wooden peg leg. After a
couple of weeks waring this new wooden peg leg the weight became no issue.
Captain Jim says "It just tweaked my right butt check."
can proudly stand behind and Captain Jim can proudly stand on.
Over a few more days Christopher would sand and sand the peg leg. Giving it an
extremely smooth finish then applying several coats of sealer. Chris installed the
carbon fiber prosthetic into the shell bonding it with a harding foam. Once this had set
up he contoured the top of he wooden peg leg to meet the contours of the carbon
fiber prosthetic. Both Jeffrey and Christopher had to be precise with these contours in
order for Captain Jim to be able to bend his leg without having any discomfort. The
hours of meticulous shaping of the peg leg had taken the height down to 22 inches
and the weight to 20 lbs. No more could be taken off the diameter of the wooden leg.
The walls of the wooded upper half had to stay thick enough so not to come apart
over time. Captain Jim came for the finish product. It was beautiful and just what he
envisioned. It was definitely more meatier looking than the old style peg leg but that's
what he wanted. Captain Jim wanted this leg to make a statement and a grand
statement this Brazilian Cherry peg leg did make. The one last concern was the
weight of this wooden peg leg. Captain Jim's other carbon fiber prosthetic legs and
peg legs weigh about 10 lbs and from the get go Chris and Jim realized that this leg
would be much heaver. A lot of time and financial investment went into this wooden
peg leg. The big question now was how long could Jim ware the leg before
it caused him discomfort due to the weight. Captain Jim slid the limb or his right leg
into this gorgeous wooden peg leg for the first time. As he walked around the shop he
became more excited with every step. Yes much heaver than his other legs but a
great fit none the less and one thing was for sure, it's a real wooden peg leg. After a
couple of weeks waring this new wooden peg leg the weight became no issue.
Captain Jim says "It just tweaked my right butt check."
| The lath machine turns the block of wood around and around while Christopher guides a hand chisel along the block of wood cutting away to shape the peg leg. He used lots of experience, patients and detail. |
As the peg leg was being shaped
we realized that it looked like a
wooden bottle. So the story now
goes... The rum in the bottle was
the Captain's anaesthetic but
when emptied the wooden bottle
became Captain Jim's prosthetic.
we realized that it looked like a
wooden bottle. So the story now
goes... The rum in the bottle was
the Captain's anaesthetic but
when emptied the wooden bottle
became Captain Jim's prosthetic.
| Brazilian Cherry Wooden Peg Leg |