1. OR-PR 156 Task 6 Replace a Broken Upright on a Metal AFO

2. 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

3. 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

4. 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

5. 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

6. Removing Broken Upright Remove the orthosis from the stirrup

7. Removing Broken Upright Remove the orthosis from the stirrup Remove the calf cuff and preserve for later reattachment

8. Removing Broken Upright Remove the orthosis from the stirrup Remove the calf cuff and preserve for later reattachment Reinstall the joint spacer fixture

9. 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

10. 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

11. 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

12. 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

13. 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

14. Removing Broken Upright Carefully center punch the rivets, producing a depression deep enough to keep a drill bit in place

15. 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

16. Removing Broken Upright Using a pin punch drive out the rivets to separate the band from the upright

17. Shaping New Upright Take a new upright attached to an ankle joint and contour it to match the traced upright line

18. Attaching New Upright Now install the new ankle joint-upright on the joint spacer fixture

19. Attaching New Upright Continue to refine the shape of the new upright until it matches up with the calf band properly

20. Attaching New Upright Rivet the new upright on the calf band Remove the joint spacer and reinstall the calf cuff on the calf band

21. 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