Thank you Tim Horton's

Of all places to find inspiration, leave it to me to find it in a semi-awake state at a Tim Horton's lineup, especially considering that I am a die-hard Java Moose guy :-)

Always trying to find the best structural and economical components, while waiting in line, I was drawn to the aluminium arms that held up their monitors. Perfect symmetry, weight reduction holes... integrated elbows via a 2 bar upper arm section bolted into a 1 bar lower arm section. Simple as pie, aesthetically pleasing and strong as hell.

Material is 6061 T-6 Aluminium
Dimension Choices:

• Main spans: 1/2" x 1.5" x length

Extremity structure settled. Thanks Tim :-B
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PS - After re-reading some best practices on Exo-Frames, I believe I have had a Eureka moment in regards to some of the recommendations from the Pacific Rim.
They recommended a 4-bar stability system for the extremity spans. Up until now, I was unable to get a solid answer from anyone as to exactly what this entails. It suddenly dawned on me while designing and re-designing the extremity spans that this means tandem bars up, and tandem bars down (instead of my single bar in the lower position).

To accomplish this, I would need some sort of Delrin-washered Aluminium spacer at the elbow to maintain the proper gap. The upper and lower insertion (body connection) points can act as their own integrated spacers (includes Delrin washers to reduce friction).

Upon further consideration, I think this would also prove to be a superior platform when it comes to mounting the actuators in a stable manner.

Why PAM turns me on :-B

Looks like Electric Hydraulics in Canada for under $1000 an actuator is a tail-chasing adventure. There are a few on EBay from time to time, but matching them and getting them to work together is more of a pain than it is worth.

I have since chosen to actuate using P.A.M. (Pneumatic Artificial Muscles). The beauty of this solution is the ease of construction and the way they mirror their bio-engineered counterparts. I can actually build these inexpensively, however, the difficult part will be the valve system that acts as a 1 – 0 Boolean switching system. As pointed out to me, pneumatic spool valves might be the answer... and also using the exhaust from one to move the other. More to follow...

For instance, we will need a biceps – triceps inverse contraction relationship. Only one can contract at any given time, never both. Using this type of valve system, it may be possible to hold a contraction at any point of a lift phase. How does this figure in? Well, this sort of contraction – relax relationship is how we are able to maintain our standing up straight stance.

This system could be powered by anything from a pair of SCUBA tanks to a small on board air compressor. Ideally I want this to be a variable-pressure power assist system, not unlike a SCUBA diver’s regulator that gives more air depending on demand, or power steering on a car.

As far as the Operating System goes, the leading contenders are:

-Redhat Linux
-Ubuntu Linux
- Windows XP (There, I said it )

Some if the integrated features will be:

-USB System Temperature Sensors
-Load Cell status indicator (Via custom Widget)
-GPS Positioning (Via custom Widget)
-Laser Rangefinder (Will be building this from an instructable)
-System fault indicator (Via custom Widget)
-Secure Wireless connectivity (802.11g WPA-2)
-VOX command system (Currently testing Smart Butler)
-Emergency system shutdown
-etc

This will all be condensed into readouts and widgets on the 800 x 600 pixel display on the (still in development) HUD.