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OR-PR 156 Task 6
Replace a Broken Upright on a Metal AFO
Introduction
Repairs to existing orthoses are common and an important skill for a technician to possess
A common repair involves the replacement of a broken upright on a metal AFO
Objectives Remove existing
broken upright Straighten out orthosis
if necessary Shape new upright to
match existing one Attach new upright Restore cuff/closure
and re-align
Removing Broken Upright Adjust a joint
spacer fixture to the width of the ankle joints (X) while the orthosis is still attached to the stirrup
X
Removing Broken Upright Adjust a joint
spacer fixture to the width of the ankle joints (X) while the orthosis is still attached to the stirrup
Set the fixture aside for later use
X
X
Removing Broken Upright Remove the
orthosis from the stirrup
Removing Broken Upright Remove the
orthosis from the stirrup
Remove the calf cuff and preserve for later reattachment
Removing Broken Upright Remove the
orthosis from the stirrup
Remove the calf cuff and preserve for later reattachment
Reinstall the joint spacer fixture
Straightening Existing AFO Place the AFO calf
band up on the bench Lay out a horizontal
line on a sheet of paper (Line A)
Then lay out a perpendicular line on the end of the horizontal line corresponding to the unbroken side of the orthosis (Line B) Line A
Line B
Straightening Existing AFO Center the AFO ankle
joints on the horizontal line so that the proximal edge of the calf band on the unbroken side is along the vertical line
Line A
Line B
Straightening Existing AFO Center the AFO ankle
joints on the horizontal line so that the proximal edge of the calf band on the unbroken side is along the vertical line
Mark the height of the calf band on the vertical line
project a horizontal line (Line C) across the paper at this height
Line C
Straightening Existing AFO
Re-contour the unbroken upright to bring the calf band to a horizontal position along Line C
Trace the broken upright on the paper
Removing Broken Upright
Sand the surface of the broken upright to expose the rivets attaching it to the calf band. The rivet surfaces should be smooth and flat
Removing Broken Upright
Carefully center punch the rivets, producing a depression deep enough to keep a drill bit in place
Removing Broken Upright
Using a countersink bit or a drill bit 2x the diameter of the rivet drill out the countersink material down to the original rivet
Removing Broken Upright
Using a pin punch drive out the rivets to separate the band from the upright
Shaping New Upright
Take a new upright attached to an ankle joint and contour it to match the traced upright line
Attaching New Upright
Now install the new ankle joint-upright on the joint spacer fixture
Attaching New Upright
Continue to refine the shape of the new upright until it matches up with the calf band properly
Attaching New Upright
Rivet the new upright on the calf band
Remove the joint spacer and reinstall the calf cuff on the calf band
Reassembling the AFO
Rivet the new upright on the calf band
Remove the joint spacer and reinstall the calf cuff on the calf band
Reattach the orthosis to the stirrup and align as needed