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Post by Ron Walker on Sept 11, 2022 19:52:58 GMT -7
Posted by: Scott T Nov 17 2018, 01:09 PM Thanks MM.
Ron -We may do a show in this location but are scheduled to go back to the Bridge Church where the project started.
A couple more photos of the complete frame.
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Post by Ron Walker on Sept 11, 2022 19:53:22 GMT -7
Posted by: Ron Walker Nov 17 2018, 02:39 PM Love the blocks, they work as well as metal "L" brackets, are much cheaper and guide the screw properly. You learn something new every day. It does look like there is "foamcore" attached. How well is that going and what are you using to attach it to the frame?
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Post by Ron Walker on Sept 11, 2022 19:53:28 GMT -7
Posted by: Strgzr Nov 19 2018, 11:47 AM That's a beautiful dome! Nice job!!
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Post by Ron Walker on Sept 11, 2022 19:53:52 GMT -7
Posted by: Scott T Nov 19 2018, 12:11 PM Thanks folks.
The covering is cut from 3mm thick foamex (foam core?/ foamalux).
This is where it really got fiddly. The technique seems to be to clamp an oversized 'petal' to the frame, then draw on cutting lines along the frame from the outside, remove the petal and cut it to size. There is not much tolerance - each petal needs to extend over the 12m thick vertical spars by 6mm on each side. When it is cut to size (using a Stanley knife) it is screwed on with very small 12mm long, 2.5mm diameter countersunk wood screws. Unfortunately each one is unique because I could not get enough precision into making the frame.
There were 32 petals and 32 side panels to make - and in the latter stages a very small hole to squeeze into and out of the dome.
I will post some more pictures later.
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Post by Ron Walker on Sept 11, 2022 19:54:05 GMT -7
Posted by: Scott T Nov 19 2018, 12:47 PM Another picture
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Post by Ron Walker on Sept 11, 2022 19:54:20 GMT -7
Posted by: Ron Walker Nov 19 2018, 02:55 PM Again, beautiful work.
I am again assuming that this entire dome structure will go on some kind of support structure perhaps two meters high thus lifting your horizon (spring) line off of the floor. I would recommend construction of 2X4 or even 2X6 for greater strength. Then you might want to consider draping that lower area with black cloth or equivalent drapery lining. This to allow emergency exit around the entire circumference of the dome in case of fire. Not at all sure if you need to clear this structure with the local fire brigade but since it will be in a more public area you will run into them sooner or later. Perhaps they will require you to spray the entire thing with some kind of fire retardant.
I also note that you still have the central construction support in place. My guess is that the framework shouldn't sag at all but if it does a little perhaps it should be allowed to before the dome skin is applied.
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Post by Ron Walker on Sept 11, 2022 19:54:33 GMT -7
Posted by: mrgare5050 Nov 19 2018, 04:21 PM Good lord thats beautiful - you could sell those at Pier One ... well maybe a smaller version..
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Post by Ron Walker on Sept 11, 2022 19:54:45 GMT -7
Posted by: Ron Walker Nov 19 2018, 07:37 PM QUOTE(mrgare5050 @ Nov 19 2018, 04:21 PM) * Good lord thats beautiful - you could sell those at Pier One ... well maybe a smaller version..
You might want to copy this excellent design.
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Post by Ron Walker on Sept 11, 2022 19:54:56 GMT -7
Posted by: mrgare5050 Nov 20 2018, 01:39 AM QUOTE(Ron Walker @ Nov 20 2018, 02:37 AM) * You might want to copy this excellent design.
I DO. I also like your triangles though.
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Post by Ron Walker on Sept 11, 2022 19:55:13 GMT -7
Posted by: Scott T Nov 20 2018, 03:32 PM Ron you are a mind reader- that is exactly the plan. Sit the dome on a circumference frame with drapes. I will post some more detail in the near future. I had to get over there today to do the foiling while I had the help of the indefatigable Dave Kerwin who has been the extra pair of hands on so many occasions over this project. Extra hands are really useful when trying to fix fiddly bits of foamex overhead!
(By foiling I mean sandwiching a layer of foil between the frame and the foamex for light proofing the dome because the foamex is reasonably translucent. )
This dome is double the diameter of the last one but I am beginning to think the amount of work on a dome increases with the square (or even the cube) of the diameter! I cannot imagine how much work your giant dome must have taken. I am starting to appreciate that job even more now.
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Post by Ron Walker on Sept 11, 2022 19:55:30 GMT -7
Posted by: Ron Walker Nov 20 2018, 07:55 PM QUOTE(Scott T @ Nov 20 2018, 03:32 PM) * Ron you are a mind reader- that is exactly the plan. Sit the dome on a circumference frame with drapes. I will post some more detail in the near future. I had to get over there today to do the foiling while I had the help of the indefatigable Dave Kerwin who has been the extra pair of hands on so many occasions over this project. Extra hands are really useful when trying to fix fiddly bits of foamex overhead!
(By foiling I mean sandwiching a layer of foil between the frame and the foamex for light proofing the dome because the foamex is reasonably translucent. )
This dome is double the diameter of the last one but I am beginning to think the amount of work on a dome increases with the square (or even the cube) of the diameter! I cannot imagine how much work your giant dome must have taken. I am starting to appreciate that job even more now.
After four years finished I walk in and cannot believe that I did it. I need to look back at the construction pictures to remind myself that I did it.
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Post by Ron Walker on Sept 11, 2022 19:55:43 GMT -7
Posted by: Scott T Nov 24 2018, 02:13 PM Sorry for sporadic posting. On 11th of November we reached a milestone in that it was the first time we removed the central support pillar from the dome. I am pleased to report that the dome did not collapse under its own weight! In fact it only seemed to sag by about an inch or so. It is interesting just how strong a hemisphere is - the earlier wangyness has gone! Photos of apex - obviously the gaps will need filling. The next job was to sandwich foil between the frame and the petals as the foamex is translucent. Makes the dome look a bit spacey (if a little wrinkled). Do robots lay eggs?
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Post by Ron Walker on Sept 11, 2022 19:55:53 GMT -7
Posted by: Ron Walker Nov 24 2018, 02:52 PM We love any posting.
That slight compression was why I was thinking let the frame settle and then cut the gores. However you could do a support from the ceiling to take that compression load off the structure. Something like a thin aircraft cable from the top of the dome through a couple of pulleys over to the side and then pull down with a small winch. Another thought would be to run a thin aircraft cable around the bottom of the dome with a turnbuckle so there is less chance of expanding because of the dome load.
To cover the cracks between the gores you might consider a white cloth type tape.
Also at the top where all the wood supports come together, I'm wondering if it would be worthwhile to place a round plywood circle on the outside to attach all of the individual parts together. That would add to the strength of the system I would think.
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Post by Ron Walker on Sept 11, 2022 19:56:03 GMT -7
Posted by: Scott T Dec 2 2018, 01:11 AM Hi - Dave has spent the last week making the circumference frame. Two rings of plywood and some rather heftily engineered uprights. Yesterday we extended the 'bird table' (the central support) to the correct height and test lifted three sections into position just to see if it was manageable. It is a three person job - one person up the mini scaffold tower to guide the tip of the segment onto the bird table and two to lift the gore onto the circumference frame. The gores are really not particularly heavy, they are just large and unwieldy. I have to say, the partial dome becomes a more imposing structure when lifted off the floor. The total height of the structure is about 4m at the apex. Despite the rather beautiful setting at the moment, we are going to transport all the pieces back the Bridge Church over the next week to set up for the Christmas show.
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Post by Ron Walker on Sept 11, 2022 19:56:14 GMT -7
Posted by: Ron Walker Dec 2 2018, 11:42 AM Just class A first rate work!
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